Dodge - Grand Caravan - Workshop Manual - 1994 - 1994 (2)

Factory Workshop Manual Make Dodge Model Grand Caravan Engine and year V6-201 3.3L (1994) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Audio Control Relay > Component Information > Locations Micro Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Body Control Module System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 10 Keyless Entry Module: Diagrams Remote Keyless Entry Module Connectors Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Programming Module Keyless Entry Module: Service and Repair Programming Module PROGRAMMING RKE MODULE The RKE module is capable of retaining up to 4 different VAC(s) when vehicle battery power is interrupted. Replacement or additional key fob transmitter VAC(s) (maximum 4) can be programmed into the Body Control Module (BCM). A functional key fob transmitter is required to program the BCM to accept the new VAC. If a functional key fob transmitter is not available, a scan tool (DRB) can be used to program the BCM. (1) Using a functional key fob, unlock the vehicle and disarm the Vehicle Theft Alarm (2) Insert ignition key into the ignition switch. (3) Switch ignition to RUN position without starting engine. (4) On a functional key fob, actuate and hold the UNLOCK button for a minimum four seconds (maximum ten seconds). (5) While holding UNLOCK button, and before ten seconds passes, actuate and release the PANIC button. A single chime will sound to verify that the RKE module is set to receive the new VAC. (6) Within 30 seconds of the chime, actuate any key on each new key fob transmitter. After 30 seconds or when ignition switch is turned OF{ the RKE module will end the programming mode. A single chime will sound to verify that the RKE module will no longer receive additional VAC(s). (7) When VAC programming is complete, turn OFF ignition switch and verify RKE system operation using each key fob. NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror systems. If a primary key fob is being replaced, the memory seat and mirror module will require programming. Refer to Group 8R, Power Seats for proper (data link) programming procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Programming Module > Page 13 Keyless Entry Module: Service and Repair Remote Keyless Entry Module Replacement REMOVAL (1) Remove instrument panel top cover. (2) Remove screws holding RKE module to instrument panel. (3) Disconnect wire connector from RKE module. (4) Remove module. INSTALLATION Reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Body Control Module System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 18 Keyless Entry Module: Diagrams Remote Keyless Entry Module Connectors Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Programming Module Keyless Entry Module: Service and Repair Programming Module PROGRAMMING RKE MODULE The RKE module is capable of retaining up to 4 different VAC(s) when vehicle battery power is interrupted. Replacement or additional key fob transmitter VAC(s) (maximum 4) can be programmed into the Body Control Module (BCM). A functional key fob transmitter is required to program the BCM to accept the new VAC. If a functional key fob transmitter is not available, a scan tool (DRB) can be used to program the BCM. (1) Using a functional key fob, unlock the vehicle and disarm the Vehicle Theft Alarm (2) Insert ignition key into the ignition switch. (3) Switch ignition to RUN position without starting engine. (4) On a functional key fob, actuate and hold the UNLOCK button for a minimum four seconds (maximum ten seconds). (5) While holding UNLOCK button, and before ten seconds passes, actuate and release the PANIC button. A single chime will sound to verify that the RKE module is set to receive the new VAC. (6) Within 30 seconds of the chime, actuate any key on each new key fob transmitter. After 30 seconds or when ignition switch is turned OF{ the RKE module will end the programming mode. A single chime will sound to verify that the RKE module will no longer receive additional VAC(s). (7) When VAC programming is complete, turn OFF ignition switch and verify RKE system operation using each key fob. NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror systems. If a primary key fob is being replaced, the memory seat and mirror module will require programming. Refer to Group 8R, Power Seats for proper (data link) programming procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Programming Module > Page 21 Keyless Entry Module: Service and Repair Remote Keyless Entry Module Replacement REMOVAL (1) Remove instrument panel top cover. (2) Remove screws holding RKE module to instrument panel. (3) Disconnect wire connector from RKE module. (4) Remove module. INSTALLATION Reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Power Door Lock Relay: Locations Micro Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 25 Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations Fig. 19 Engine Compartment Wiring Mounted on left fender side shield. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 30 ABS Main Relay: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect wiring harness electrical connectors from relays, then remove screw securing relay assembly to left front inner fender. 3. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Locations Brake Fluid Pump Relay: Locations Fig. 19 Engine Compartment Wiring Mounted on left fender side shield. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams ABS Module Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 37 Electronic Brake Control Module: Description and Operation The Controller Anti-Lock Brake (CAB) is located on the front lefthand side of the engine compartment. The CAB uses the information from the wheel speed sensors to control the anti-lock brake system function. The CAB also monitors ABS operation and detects system faults. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 38 Electronic Brake Control Module: Service and Repair 1. With ignition switch in Off position, disconnect both battery cables and remove battery, then remove battery tray from vehicle. 2. Remove Controller Anti-lock Brake (CAB) from battery tray support bracket. 3. Loosen bolt securing 60-way connector to CAB, then disconnect connector from CAB by pulling straight out. Do not twist connector. 4. Remove CAB with its mounting bracket from vehicle. 5. Reverse procedure to install, noting the following: a. Ensure ignition switch is still in Off position before connecting 60-way connector to CAB. b. Torque connector bolt to 38 inch lbs. and CAB assembly mounting bolt to 14 inch lbs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations Radiator Fan Relay: Locations Radiator Fan Relay is located in the Power Distribution Center. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 43 Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 44 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions Radiator Fan Relay: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 47 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 48 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 49 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 50 Radiator Fan Relay: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 51 Radiator Fan Relay: Electrical Diagrams Air Conditioning System (Part 1 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 52 Air Conditioning System (Part 2 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 53 Air Conditioning System (Part 3 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 54 Air Conditioning System (Part 4 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 55 Radiator Fan System With Heater Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 56 Heater System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation Blower Motor Relay: Description and Operation Chrysler does not use a Blower Motor Relay for these Year/Make/Model Vehicles. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 64 In Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 65 Compressor Clutch Relay: Description and Operation Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 66 In Power Distribution Center PURPOSE Supplies ground path for A/C compressor clutch. OPERATION Controlled by A/C or defrost switch (inside vehicle) and Powertrain Control Module (PCM). Relay receives battery voltage from radiator fan relay , (A/C relay will not energize unless the radiator fan relay is energized). When A/C or defrost is selected, (turned ON), inside vehicle, and low and high pressure switches are closed, PCM receives an A/C ON signal. PCM then supplies relay ground. If PCM senses Wide Open Throttle (WOT) or low idle speed condition, it removes relay ground, discontinueing A/C clutch engagement. PCM delays activation of A/C relay for a specific period after engine start-up. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Engine Compartment Components RH Side Of Engine Compartment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Speedometer Module: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 82 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 83 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Speedometer Module: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 89 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 90 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations Backup Lamp Relay: Locations In Power Distribution Center The Backup Lamp Relay is located in the Power Distribution Box. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 95 Power Distribution Center As shown, the Backup Lamp Relay is in the bottom row center. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 96 Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions Daytime Running Lamp Control Unit: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 102 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 103 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 104 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 105 Daytime Running Lamp Control Unit: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 106 Daytime Running Lamp Module Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 107 Daytime Running Lamp Control Unit: Electrical Diagrams Daytime Running Lamp Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 108 Fog Lamp System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Micro Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Locations Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations Turn Signal Relay: Locations Relay Block Combination flasher relay plugs into the lower left corner of the relay bank located to the left of the fuse block. Remove the lower steering wheel column cover for access. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 132 Micro Relay Block: Locations Power Distribution Center Identification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 133 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 134 Fig. 17 Relay Bank Identification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 135 Micro Relay Block: Locations Micro Relay Block and Relay Bank Location Relay Bank is located near the fuse box and Micro Relay Bank is located behind center of instrument panel. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions Micro Relay Block: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 138 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 139 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 140 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 141 Micro Relay Block: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 142 Micro Relay Block: Connector Views Micro Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 143 Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 144 Micro Relay Block: Electrical Diagrams Power Distribution Center (Part 1 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 145 Power Distribution Center (Part 2 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 146 Power Distribution Center (Part 3 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 147 Power Distribution Center (Part 4 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly Body Controller: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 158 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly Body Controller: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly > Page 164 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > Page 165 Body Control Module System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Body Controller: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 168 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 169 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 170 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 171 Body Controller: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 172 Body Controller: Connector Views Body Control Module Blue Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 173 Body Control Module Natural Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 174 BCM Natural Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 175 BCM Blue Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and ID > BCM Identification Body Controller: Application and ID BCM Identification There are two different body control modules available on these vehicles; One supports the mechanical instrument cluster as well as the electro/mechanical instrument cluster. - The other supports the electronic instrument cluster. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and ID > BCM Identification > Page 178 Body Controller: Application and ID Glossary of Terms BCM - Body Control Module CCD - Chrysler Collision Detection (Vehicle Communications Bus) CMTC - Compass/mini-trip Computer (module) DLC - Data Link Connector (previously Called "Diagnostic Connector") DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument Cluster ET - Elapsed Time IOD - Ignition Off Draw MET - Metric MIC - Mechanical Instrument Cluster ODO - Odometer PCM - Powertrain Control Module PDC - Power Distribution Center RKE Remote Keyless Entry Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and ID > Page 179 Body Controller: Description and Operation PURPOSE The body control module: Provides power or ground for a variety of systems and uses a voltage drop to monitor these systems. - Is the only module that has the capability of providing both bias and termination on the CCD bus system. - Is used to store odometer information displayed in the electronic instrument cluster. OPERATION The body systems are monitored by individual control modules, which send information about their operation to the body control module over the CCD (Chrysler Collision Detection multiplex system) bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed to the appropriate module(s). - Each module receives the same information about a component or circuit as another module does. - This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. BODY SYSTEM COVERAGE: - Automatic Door Locks - Compass/mini-trip Module - Courtesy Lamps - Electronic Instrument Cluster (EIC) - Electro/mechanical Instrument Cluster - Mechanical Instrument Cluster (MIC) - Illuminated Entry - Remote Keyless Entry (RKE) - Intermittent Wipers - Liftgate Release NOTE: Communication over the CCD bus is essential to the proper operation of vehicle on-board diagnostic systems and scan tool communication. Bus or scan tool problems must be corrected before proceeding with diagnostic testing. If there is a problem, refer to Vehicle Communications (CCD) Bus/Testing and Inspection for diagnosis and repair procedures. TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is not set or if it is set incorrectly, any speed-related accessories will not operate or will operate inaccurately. - This includes the speedometer, speed control, rolling door locks, and other devices that are operated by the powertrain and body controllers. - For instructions on setting the pinion factor, see the appropriate transmission section. GLOSSARY OF TERMS BCM - Body Control Module CCD - Chrysler Collision Detection (vehicle Communications Bus) CMTC - Compass/mini-trip Computer (module) DLC - Data Link Connector (previously Called "diagnostic Connector") DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument Cluster ET - Elapsed Time IOD - Ignition Off Draw MET - Metric MIC - Mechanical Instrument Cluster ODO - Odometer PCM - Powertrain Control Module PDC - Power Distribution Center RKE Remote Keyless Entry Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Controller: Component Tests and General Diagnostics Diagnostic Notes - Read First TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is not set or if it is set incorrectly, any speed-related accessories will not operate or will operate inaccurately. - This includes the speedometer, speed control, rolling door locks, and other devices that are operated by the powertrain and body controllers. - For instructions on setting the pinion factor, see the appropriate transmission section. NOTE: These diagnostics are based on the failure condition or symptom being present at the time of diagnosis. TIPS: Verify that the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Be careful when performing electrical tests to prevent accidental shorting of terminals. Such mistakes can damage fuses or components and will sometimes set a second code, making diagnosis of the original problem more difficult. WARNINGS: - When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as watchbands or bracelets that might make an inadvertent electrical contact. - When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests. To efficiently diagnose CCD bus problems follow these six steps: 1. Verify Complaint 2. Check for Related Symptoms 3. Analyze Symptoms 4. Isolate the Problem 5. Repair the Isolated Problem 6. Verify Proper Operation ROAD TESTING Some complaints will require a test drive to duplicate the diagnostic code or symptom condition and to verify the repair. CAUTIONS: Before road testing a vehicle, be sure that all components are reassembled. - During the test drive, do not try to read the scan tool screen while in motion. - Do not hang the scan tool from the rear view mirror or operate it yourself. Have an assistant available to operate the scan tool. TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is not set or if it is set incorrectly, any speed-related accessories will not operate or will operate inaccurately. - This includes the speedometer, speed control, rolling door locks, and other devices that are operated by the powertrain and body controllers. - For instructions on setting the pinion factor, see the appropriate transmission section. Description of On-Board Diagnostics A scan tool is required to read body system trouble codes. However, not all body system problems have a corresponding trouble code. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 182 Body Controller: Scan Tool Testing and Procedures If the scan tool Does Not Power Up; Check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). If all connections are proper between scan tool and the vehicle, and the vehicle battery is fully charged, an inoperative scan tool may be the result or faulty cable or vehicle wiring. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and Inspection > Page 183 Body Controller: Tools and Equipment The following tools are recommended to properly diagnose CCD bus problems: - Scan tool -- with correct cartridge and applicable connectors. - Jumper Wires - Ohmmeter - Oil Pressure Gauge - Voltmeter Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > High Altitude Kit - Installation Powertrain Control Module: Technical Service Bulletins High Altitude Kit - Installation NO.: 25-01-93 GROUP: Emissions DATE: Sep. 3, 1993 SUBJECT: High Altitude Kits MODELS: 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country SYMPTOM/CONDITION: The 1994 AS Body Owners Manual makes reference to the availability of high altitude kits (1st page of the Starting and Operating section) that can be used if the owner changes his residence from an area of low altitude to one of high altitude. These kits are required by the EPA for some 1994 federally certified AS body vehicles to comply with high altitude emissions standards. The high altitude kit will have no effect on vehicle performance or driveability. DIAGNOSIS: Vehicles for which these kits are available have the following statement on the Vehicle Emission Control Information (VECI) label: "CONVERSION KIT REQUIRED FOR HIGH ALTITUDE - SEE OWNERS MANUAL". The high altitude kit must be installed if requested by the vehicle owner, at the owner's expense. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the PCM, VECI label and installing an Authorized Modification label. 1. Using the procedure outlined on either page 14-51 or 14-112 of the 1994 Front Wheel Drive/All Wheel Drive Van/Wagon Service Manual, replace the PCM with the appropriate PCM specified in the "Parts Required" section of this bulletin. 2. Use Mopar Tar Remover (P/N 4549601) to clean the surface of the VECI label and the area of the dash panel that the new labels will be attached to. 3. Attach the new VECI label on top of the original label. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > High Altitude Kit - Installation > Page 188 4. Type in the required information on the Authorized Modification label (P/N 4275086) as illustrated, and attach next to the VECI label. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations Powertrain Control Module (PCM) And Data Link Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 191 Powertrain Control Module (PCM) And Data Link Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 194 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 195 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 196 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 197 Powertrain Control Module: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 198 Powertrain Control Module 60 Way Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Auto Sutdown Relay In the Power Distribution Center left side of engine compartment. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 202 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 203 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 206 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 207 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 208 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 209 Automatic Shut Down (ASD) Relay: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 210 Automatic Shut Down (ASD) Relay: Description and Operation Relay Locations PURPOSE Relay supplies battery voltage to the ignition coil and fuel injector(s). OPERATION Ignition switch in the START or RUN position, and PCM is receiving reference signals from the distributor pick-up. The Powertrain Control Module (PCM) activates the relay (by supplying a ground). If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM interrupts the relay ground and no voltage is supplied to the ignition coil, or fuel injector(s). NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through the same ground circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay NOTE: Relay terminal numbers can be found on the bottom of the relay: TERMINAL IDENTIFICATION - Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times. - Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the components being operated. - Terminal number 86 is connected to a switched (B+) power source (ignition in ON or RUN). - Terminal number 85 is grounded by the PCM. PROCEDURE 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value (ohms) should be 75 ± 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 Volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. Continuity should now be present between terminals number 87 and 30. Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 Volt power source. - If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring Diagrams for fuel system wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center (Relay Locations) Fuel Pump Relay Socket Fuel pump relay is located in LH side of engine compartment in the power distribution center. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 217 Fuel Pump Relay: Description and Operation Relay Locations PURPOSE Relay supplies battery voltage to the fuel pump and oxygen sensor heater element, when grounded by the Powertrain Control Module (PCM). OPERATION The PCM grounds the relay when the ignition switch is in the START or RUN position and the PCM is receiving reference signals from the distributor pick-up. If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM interrupts the relay ground and no voltage is supplied to the fuel pump and oxygen sensor heater element. NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through the same ground circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 218 Fuel Pump Relay: Testing and Inspection NOTE: The relay terminal numbers can be found on the bottom of the relay: TERMINAL IDENTIFICATION - Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times. ^ Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the component being operated. - Terminal number 86 is connected to a switched (+) power source. - Terminal number 85 is grounded by the PCM. PROCEDURE 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value (ohms) should be 75 ± 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 Volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. Continuity should now be present between terminals number 87 and 30. Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 Volt power source. - If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring Diagrams for fuel system wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Auto Sutdown Relay In the Power Distribution Center left side of engine compartment. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 222 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 223 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 226 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 227 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 228 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 229 Automatic Shut Down (ASD) Relay: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 230 Automatic Shut Down (ASD) Relay: Description and Operation Relay Locations PURPOSE Relay supplies battery voltage to the ignition coil and fuel injector(s). OPERATION Ignition switch in the START or RUN position, and PCM is receiving reference signals from the distributor pick-up. The Powertrain Control Module (PCM) activates the relay (by supplying a ground). If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM interrupts the relay ground and no voltage is supplied to the ignition coil, or fuel injector(s). NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through the same ground circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay NOTE: Relay terminal numbers can be found on the bottom of the relay: TERMINAL IDENTIFICATION - Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times. - Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the components being operated. - Terminal number 86 is connected to a switched (B+) power source (ignition in ON or RUN). - Terminal number 85 is grounded by the PCM. PROCEDURE 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value (ohms) should be 75 ± 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 Volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. Continuity should now be present between terminals number 87 and 30. Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 Volt power source. - If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring Diagrams for fuel system wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 238 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 239 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 240 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 241 Ignition Control Module: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Locations Air Bag Control Module And Body Control Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Diagrams > Air Bag Control Module 4 Way Connector Air Bag Control Module Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Diagrams > Air Bag Control Module 4 Way Connector > Page 248 Air Bag Control Module Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Diagrams > Air Bag Control Module 4 Way Connector > Page 249 Airbag System Control Module Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information Supplemental Restraint System (SRS) Control Module: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information > Page 252 Supplemental Restraint System (SRS) Control Module: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information > Page 253 Supplemental Restraint System (SRS) Control Module: Vehicle Damage Warnings CAUTION: Before disconnecting any control module connector, make sure the ignition is "OFF" and the battery is disconnected. Failure to do so could damage the module. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Page 254 Supplemental Restraint System (SRS) Control Module: Description and Operation OPERATION The deceleration or g-force resulting from the impact of a front-end collision causes the electronic sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying the air bags. The total time between determining to deploy and deflation of the air bag is 1/10th of a second. SELF DIAGNOSTIC FUNCTIONS Whenever the ignition key is turned to the "RUN" or "START" position, the air bag control module (ACM) performs a lamp check by turning the AIR BAG warning lamp ON. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. The air bag system is monitored by the ACM. The ACM monitors critical input and output circuits within the air bag system, making sure they are operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The ACM provides diagnostic information about the air bag system to the technician through the DRB via the CCD bus. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Testing and Inspection > Component Tests and General Diagnostics Supplemental Restraint System (SRS) Control Module: Component Tests and General Diagnostics GENERAL INSPECTION A visual inspection consists of physically looking for possible cause of a malfunction. A careful and thorough visual inspection of components may quickly identify malfunction cause and eliminate need for diagnostic testing. If a malfunction is not resolved by visual inspection, proceed with diagnostic testing. 1. On models equipped with front impact sensors, ensure both sensors are properly install with three fasteners each. 2. On all models, turn ignition switch to On. 3. If air bag warning lamp does not light, proceed with diagnostic testing. 4. If air bag warning lamp fails to go out after ten seconds, proceed with diagnostic testing. 5. Check air bag control module (ACM) case and brackets for dents, cracks or deformities. 6. Check ACM connectors and lock levers for damage and terminals for deformities. 7. Remove air bag module as outlined under Component Service. 8. Never attempt to measure circuit resistance of air bag module even with a specified tester. 9. Check air bag pad cover for dents, cracks or deformities. 10. Check air bag module for dents, cracks or deformities. 11. Check hooks and connectors for damage, terminals for deformities and harness for binds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 257 Supplemental Restraint System (SRS) Control Module: Scan Tool Testing and Procedures Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Testing and Inspection > Page 258 Supplemental Restraint System (SRS) Control Module: Service and Repair AIR BAG CONTROL (ACM), REPLACE 1. Disarm air bag system as outlined under Air Bag System Disarming and Arming. See: Body and Frame/Interior Moulding / Trim/Dash Panel/Air Bag(s) Arming and Disarming/Service and Repair 2. Remove screws attaching lower console to instrument panel support bracket. 3. Remove upper console attaching screws behind cup holder, then slide console to rear and up to remove. 4. Disconnect ACM wiring and remove module, then remove ACM mounting screws. 5. Reverse procedure to install and tighten screws to specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 263 In Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 264 Starter Relay: Testing and Inspection Fig 4 Starter Relay Tests 1. Remove starter relay from relay center. 2. Perform testing procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 275 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 276 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 277 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 278 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 279 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 280 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Control Module: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 285 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 286 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts Control Module: Customer Interest A/T - Harsh Gear Engagement/Upshifts/Downshifts NO.: 21-36-93 GROUP: Transmission DATE: Dec. 10, 1993 SUBJECT: Improved Transmission Shift Schedule MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH 09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION. SYMPTOM/CONDITION: Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1 kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary Neutral/Drive garage shifts. Park to Reverse noise (grunt). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4686478 Transmission Control Module AR 4467721 Transmission Fluid - ATF Plus (7176) REPAIR PROCEDURE: This repair involves the replacement of the transmission control module with a module that incorporates revised software, changing the transmission fluid, setting the pinion factor, and transaxle quick learn. 1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is currently installed on the vehicle. This is accomplished by choosing the TSB option under Adjustments. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS INSPECTED AT THE RETURN CENTER. 2. Replace the transmission control module with the new module, following the procedures outlined in the appropriate service manual. 3. Change the transmission fluid following the procedure outlined in the service manual. NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER. 4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and then place gear selector in Neutral. 5. Using the procedures listed in the service manual complete the following: a. Quick Learn Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 291 b. Electronic Pinion Factor Procedure 6. Drive the vehicle at least 10 miles. 7. Change the transmission fluid again following the procedure outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-06-90 2.1 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 297 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 298 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 299 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 300 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 301 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 302 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Control Module: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 307 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 308 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts Control Module: All Technical Service Bulletins A/T - Harsh Gear Engagement/Upshifts/Downshifts NO.: 21-36-93 GROUP: Transmission DATE: Dec. 10, 1993 SUBJECT: Improved Transmission Shift Schedule MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH 09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION. SYMPTOM/CONDITION: Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1 kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary Neutral/Drive garage shifts. Park to Reverse noise (grunt). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4686478 Transmission Control Module AR 4467721 Transmission Fluid - ATF Plus (7176) REPAIR PROCEDURE: This repair involves the replacement of the transmission control module with a module that incorporates revised software, changing the transmission fluid, setting the pinion factor, and transaxle quick learn. 1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is currently installed on the vehicle. This is accomplished by choosing the TSB option under Adjustments. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS INSPECTED AT THE RETURN CENTER. 2. Replace the transmission control module with the new module, following the procedures outlined in the appropriate service manual. 3. Change the transmission fluid following the procedure outlined in the service manual. NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER. 4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and then place gear selector in Neutral. 5. Using the procedures listed in the service manual complete the following: a. Quick Learn Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 313 b. Electronic Pinion Factor Procedure 6. Drive the vehicle at least 10 miles. 7. Change the transmission fluid again following the procedure outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-06-90 2.1 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor Axle Ratio Values Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values NO.: 08-39-93 Rev. A GROUP: Electrical DATE: Sep. 17, 1993 SUBJECT: 41TE Pinion Factor Axle Ratio Values NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** MODELS: **1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue ** DISCUSSION: When installing a replacement TCM (Transmission Control Module), it is necessary to set the pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the speedometer indicates correctly. One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the correct axle ratios for the various applications: YEAR ENGINE SIZE RATIO 1993 3.8L 3.19 3.0L and 3.3L 3.62 1994 3.8L 3.45 3.0L and 3.3L 3.62 POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor Axle Ratio Values Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values NO.: 08-39-93 Rev. A GROUP: Electrical DATE: Sep. 17, 1993 SUBJECT: 41TE Pinion Factor Axle Ratio Values NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** MODELS: **1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue ** DISCUSSION: When installing a replacement TCM (Transmission Control Module), it is necessary to set the pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the speedometer indicates correctly. One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the correct axle ratios for the various applications: YEAR ENGINE SIZE RATIO 1993 3.8L 3.19 3.0L and 3.3L 3.62 1994 3.8L 3.45 3.0L and 3.3L 3.62 POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module Transmission Control Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 325 Power Control Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 326 Control Module: Locations Power Distribution Center Power Distribution Center Fuse Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 329 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 330 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 331 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 332 Control Module: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 333 Control Module: Connector Views Part 1 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 334 Part 2 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 335 Part 3 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 336 Part 4 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 337 Part 5 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 338 Part 6 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 339 Part 7 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 340 Part 8 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 341 Part 9 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 342 Part 10 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 343 Part 11 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 344 Transmission Control Schematic Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information Control Module: Description and Operation General Information Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 347 The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transaxle. The TCM receives information from several inputs, and selects the operational mode of the transaxle. Some of the inputs are used only by the TCM, while others are shared with other control modules on the CCD Bus. Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for operating conditions. This is to determine the desired gear range the transaxle must be operated in. The actual shift points within each shift schedule have been predetermined for the best transaxle operation, and are stored in the TCM's ROM memory. Once a TCM is installed during service, the following procedures must be performed: - Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the vehicle - Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes and final drive ratios on 1993 and newer vehicles The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the TCM learning process. The vehicle must still be driven and shifted several times in each gear range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool. NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module display on the DRB III scan tool Emission regulations require the use of two labels after a flash update: - Emission Modification Label - Emission Part Number Modification Label The following provides information on TCM identification and flash programming application: 1989 - 92 Original controllers were non-finned and are non-flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit 1993 - 95 Original controllers were finned with four heat sinks and are flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This TSB also lists the 1990 vehicles that require a wiring modification to pin 49. 1996 Original controllers were finned with seven heat sinks and are flashable - Replacement controllers have fins with seven heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the common DLC Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 348 Control Module: Description and Operation Electronic Transmission Controller Operation LOCATION The EATX control module is located under the hood, in a potted, die cast aluminum housing with a sealed, 60-way connector. ADAPTIVE CONTROLS These controls function by reading the input and output speeds over 140 times a second and responding to each new reading. - This provides the precise friction element control needed to make smooth clutch-to-clutch shifts for all gear changes. As with most automatic transaxles, all shifts involve releasing one element and applying a different element. - In simplified terms, the upshift logic allows the releasing element to slip backwards slightly, to ensure that it does not have excess capacity; the apply element is filled until it begins to make the speed change to the higher gear; its apply pressure is then controlled to maintain the desired rate of speed change until the shift is complete. The key to providing excellent shift quality is precision; EXAMPLE As mentioned, the release element for upshifts is allowed to slip backwards slightly; the amount of that slip is typically less than a total of 20 degrees. LEARNING To achieve that precision, the EATX control module learns the characteristics of the particular transaxle that it is controlling. - It learns the release rate of the releasing element and the apply time of the applying element. - It also learns the rate at which the apply element builds pressure sufficient to begin making the speed change. - This method achieves more precision than would be possible with exacting tolerances. It can also adapt to any changes that occur with age or environment, for example, altitude, temperature, engine output, etc. KICKDOWN SHIFTING For kickdown shifts, the control logic allows the releasing element to slip and then controls the rate at which the input (and engine) accelerate; when the lower gear speed is achieved, the releasing element reapplies to maintain that speed until the apply element is filled. This provides quick response since the engine begins to accelerate immediately and a smooth torque exchange since the release element can control the rate of torque increase. This control can make any power train feel more responsive without increasing harshness. SUMMARY Adaptive controls respond to input speed changes They compensate for changes in engine or friction element torque and provide good, consistent shift quality for the life of the transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information Control Module: Service and Repair General Information Do not interchange Transmission Control Modules with previous-year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: - Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information > Page 351 Control Module: Service and Repair Replacement NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner. REMOVAL 1. Disconnect the battery negative cable. 2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect the 60 way connector on Transmission Control Module. 3. Remove Transmission Control Module mounting screws and lift module from vehicle. INSTALLATION To install, reverse removal procedures. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Transmission Control Relay Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Transmission Control Relay > Page 356 Transmission Control System Relay: Locations Transmission (Safety Shut-Down) Relay Transmission Relay Location The Transmission Relay is located in LH side of engine compartment in the Power Distribution Center. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Transmission Control Relay > Page 357 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 358 Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations > Page 363 Back Up Lamp Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation Brake Fluid Pressure Sensor/Switch: Description and Operation The switch activates a light on the dash panel to indicate that one of the hydraulic systems has failed. There are two basic types of switches. In some earlier models, as pressure falls in one system, the normal pressure of the other system forces the piston to the inoperative side where it contacts the switch terminal, causing the warning lights to illuminate. On most models, the brake warning switch is of the latching type. If a pressure loss occurs in one side of the system, the piston in the valve is forced toward the failed side where it latches in position and illuminates the warning light. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously Wheel Speed Sensor: Customer Interest ABS - Warning Light ON Continuously NO: 05-22-94 GROUP: Brakes EFFECTIVE DATE: Dec. 2, 1994 SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor Connector MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) SYMPTOM/CONDITION: Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles brake system will perform as a non-ABS equipped vehicle normally would during this condition. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair as necessary. If an ABS wheel speed sensor DTC is discovered: 1. Disconnect the 2 way connector of the suspect wheel speed sensor. 2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body harness connector. There should be resistance/interference felt between the male and female terminals. 3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic Procedures for further diagnostics. 4. If no resistance/interference is felt at one or both terminals, perform the repair procedure. PARTS REQUIRED: 1 4797997 Kit, Terminal Repair Kit Consists Of: 1 4625196 Terminal, Male 1 Connector/Wire Assembly 2 4778570 Tube, Heat Shrink REPAIR PROCEDURE: This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread female terminals. 1. Cut off the suspect body harness connector and discard. 2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and the new connector/wire assembly. 3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and spread the strands of the wire. 4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands together with the strands prepared in step 3 and twist together. 5. Solder the wires together with ROSIN core solder. 6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 7. Repeat steps 3 - 6 for the other wires. 8. Connect the body harness to the wheel speed sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously > Page 385 9. Test drive the vehicle and verify proper operation of the ABS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-18-97 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: All Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 391 39 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 392 43 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 393 45 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 394 47 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 395 51 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 396 55 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 397 57 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 398 59 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 399 63 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 400 67 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 401 69 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 402 71 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 403 173 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 404 177 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 405 179 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 406 181 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 407 187 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 408 191 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 409 193 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 410 195 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 411 201 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 412 205 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 413 207 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 414 209 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 415 256 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously Wheel Speed Sensor: All Technical Service Bulletins ABS - Warning Light ON Continuously NO: 05-22-94 GROUP: Brakes EFFECTIVE DATE: Dec. 2, 1994 SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor Connector MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) SYMPTOM/CONDITION: Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles brake system will perform as a non-ABS equipped vehicle normally would during this condition. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair as necessary. If an ABS wheel speed sensor DTC is discovered: 1. Disconnect the 2 way connector of the suspect wheel speed sensor. 2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body harness connector. There should be resistance/interference felt between the male and female terminals. 3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic Procedures for further diagnostics. 4. If no resistance/interference is felt at one or both terminals, perform the repair procedure. PARTS REQUIRED: 1 4797997 Kit, Terminal Repair Kit Consists Of: 1 4625196 Terminal, Male 1 Connector/Wire Assembly 2 4778570 Tube, Heat Shrink REPAIR PROCEDURE: This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread female terminals. 1. Cut off the suspect body harness connector and discard. 2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and the new connector/wire assembly. 3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and spread the strands of the wire. 4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands together with the strands prepared in step 3 and twist together. 5. Solder the wires together with ROSIN core solder. 6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 7. Repeat steps 3 - 6 for the other wires. 8. Connect the body harness to the wheel speed sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously > Page 420 9. Test drive the vehicle and verify proper operation of the ABS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-18-97 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 050694 > Apr > 94 > Antilock Brake System - Wheel Speed Sensor Diagnosis Wheel Speed Sensor: All Technical Service Bulletins Antilock Brake System - Wheel Speed Sensor Diagnosis NO: 05-06-94 GROUP: Brakes DATE: Apr. 1, 1994 SUBJECT: Bendix Antilock-4 Wheel Speed Sensor Diagnosis MODELS: 1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1994 (AP) Shadow/Shadow Convertible/Sundance 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH BENDIX ANTILOCK-4 ABS. DISCUSSION: Bendix Antilock-4 ABS wheel speed sensors that have been returned under warranty for inspection have been and are continuing to be tested. An unusually large number of these wheel speed sensors are being found to have no defects. The following steps must be followed when diagnosing Bendix Antilock-4 ABS equipped vehicles: The diagnostic manual MUST be followed without exception. No shortcuts should be used during the diagnostic procedure. All diagnostic work Must begin with test "1A". All diagnostic work MUST end with "VER-1A". Following the above steps will ensure correct diagnosis of Bendix Antilock-4 ABS issues as well as preventing an unnecessary increase in Expense Per Unit Repaired (EPUR) for your dealership. POLICY: Information only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 051793A > Dec > 93 > ABS - Wheel Speed Sensor Applications Wheel Speed Sensor: All Technical Service Bulletins ABS - Wheel Speed Sensor Applications NO.: 05-17-93 Rev. A GROUP: Brakes DATE: Dec. 22, 1993 SUBJECT: Left Front Wheel Speed Sensor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-17-93 DATED NOV. 12, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1991-1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN ANTILOCK BRAKE SYSTEM (ABS). DISCUSSION: On the vehicles listed above, there are two wheel speed sensors specified for the left front wheel, depending upon the model year. The difference between the two parts is the length of the wiring, and they should not be interchanged. P/N 4683057 has longer wiring and must be used only on **1993 and** 1994 model vehicles. If this part is used on prior model year vehicles the wiring may become damaged. P/N 4509213 must be used only on 1991 ** and 1992 ** model vehicles. If this part is used on a ** later ** model vehicle, the wiring is too short and would have to be routed improperly to connect to the vehicle wiring harness. This may cause damage to the wheel speed sensor wiring. This bulletin supersedes any information in the Mopar Parts Catalog or PAIS at this time. A parts catalog bulletin is being developed and the parts catalog will be revised at a later date. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: All Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 434 39 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 435 43 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 436 45 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 437 47 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 438 51 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 439 55 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 440 57 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 441 59 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 442 63 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 443 67 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 444 69 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 445 71 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 446 173 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 447 177 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 448 179 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 449 181 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 450 187 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 451 191 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 452 193 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 453 195 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 454 201 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 455 205 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 456 207 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 457 209 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 458 256 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 050694 > Apr > 94 > Antilock Brake System - Wheel Speed Sensor Diagnosis Wheel Speed Sensor: All Technical Service Bulletins Antilock Brake System - Wheel Speed Sensor Diagnosis NO: 05-06-94 GROUP: Brakes DATE: Apr. 1, 1994 SUBJECT: Bendix Antilock-4 Wheel Speed Sensor Diagnosis MODELS: 1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1994 (AP) Shadow/Shadow Convertible/Sundance 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH BENDIX ANTILOCK-4 ABS. DISCUSSION: Bendix Antilock-4 ABS wheel speed sensors that have been returned under warranty for inspection have been and are continuing to be tested. An unusually large number of these wheel speed sensors are being found to have no defects. The following steps must be followed when diagnosing Bendix Antilock-4 ABS equipped vehicles: The diagnostic manual MUST be followed without exception. No shortcuts should be used during the diagnostic procedure. All diagnostic work Must begin with test "1A". All diagnostic work MUST end with "VER-1A". Following the above steps will ensure correct diagnosis of Bendix Antilock-4 ABS issues as well as preventing an unnecessary increase in Expense Per Unit Repaired (EPUR) for your dealership. POLICY: Information only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 051793A > Dec > 93 > ABS - Wheel Speed Sensor Applications Wheel Speed Sensor: All Technical Service Bulletins ABS - Wheel Speed Sensor Applications NO.: 05-17-93 Rev. A GROUP: Brakes DATE: Dec. 22, 1993 SUBJECT: Left Front Wheel Speed Sensor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-17-93 DATED NOV. 12, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1991-1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN ANTILOCK BRAKE SYSTEM (ABS). DISCUSSION: On the vehicles listed above, there are two wheel speed sensors specified for the left front wheel, depending upon the model year. The difference between the two parts is the length of the wiring, and they should not be interchanged. P/N 4683057 has longer wiring and must be used only on **1993 and** 1994 model vehicles. If this part is used on prior model year vehicles the wiring may become damaged. P/N 4509213 must be used only on 1991 ** and 1992 ** model vehicles. If this part is used on a ** later ** model vehicle, the wiring is too short and would have to be routed improperly to connect to the vehicle wiring harness. This may cause damage to the wheel speed sensor wiring. This bulletin supersedes any information in the Mopar Parts Catalog or PAIS at this time. A parts catalog bulletin is being developed and the parts catalog will be revised at a later date. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 467 Wheel Speed Sensor: Description and Operation The wheel speed sensors are located at each wheel and transmit wheel speed information to the Controller Anti-Lock Brake (CAB). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front 1. Raise and support vehicle, then remove wheel and tire assembly. Fig. 252 Front Wheel Speed Sensor Assembly 2. Remove screw from clip that retains sensor wiring grommet, then pull sensor grommet from fenderwell. 3. Disconnect electrical connector, then remove two screws retaining sensor wiring routing tube. 4. Remove sensor head screw, then the sensor head from steering knuckle. NOTE: If sensor head is seized, use a punch and gently rock sensor back and forth until free. Do not use pliers on sensor head. 5. Reverse procedure to install. Coat sensor with suitable high temperature E.P. grease and torque mounting bolt to 5 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 470 Wheel Speed Sensor: Service and Repair Rear 1. Raise and support vehicle, then remove wheel and tire assembly. 2. Remove sensor wiring grommet retainer bracket, then pull sensor grommet from underbody. 3. Disconnect electrical connector, then remove wiring to frame rail attaching bracket. 4. Remove rear axle U-bolt nuts, then the sensor assembly mounting bracket. 5. Remove sensor head screw, then the sensor head from steering knuckle. If sensor head is seized, use a punch and gently rock sensor back and forth until free. Do not use pliers on sensor head. 6 Reverse procedure to install, noting the following: a. Torque sensor mounting bolt to 5 ft. lbs. b. Torque U-bolt nuts to 65 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications NOTE: For information on how this type of sensor operates SEE, Powertrain Management/Computers and Control Systems/Coolant Temperature Sensor/Description and Operation. NOTE: Measure resistance using a high impedance Digital Volt Ohmmeter (DVOM). COLD CURVE (Reference voltage routed to sensor through PCM internal resistance of 10k ohm) Temperature ........................................................................................................................................ ........................................ Voltage -20° F ................................................................................................................................................... ....................................... 4.70 V -10° F ................................................................................................................................................... ....................................... 4.57 V 0° F ...................................................................................................................................................... ...................................... 4.45 V 10° F .................................................................................................................................................... ....................................... 4.30 V 20° F .................................................................................................................................................... ....................................... 4.10 V 30° F .................................................................................................................................................... ....................................... 3.90 V 40° F .................................................................................................................................................... ....................................... 3.60 V 50° F .................................................................................................................................................... ....................................... 3.30 V 60° F .................................................................................................................................................... ....................................... 3.00 V 70° F .................................................................................................................................................... ....................................... 2.75 V 80° F .................................................................................................................................................... ....................................... 2.44 V 90° F .................................................................................................................................................... ....................................... 2.15 V 100° F .................................................................................................................................................. ........................................ 1.83 V 110° F .................................................................................................................................................. ........................................ 1.57 V 120° F .................................................................................................................................................. ........................................ 1.25 V HOT CURVE (Reference voltage routed to sensor through PCM internal resistance of 10 k ohm) Temperature ........................................................................................................................................ ........................................ Voltage 110° F .................................................................................................................................................. ........................................ 4.20 V 120° F .................................................................................................................................................. ........................................ 4.00 V 130° F .................................................................................................................................................. ........................................ 3.77 V 140° F .................................................................................................................................................. ........................................ 3.60 V 150° F .................................................................................................................................................. ........................................ 3.40 V 160° F .................................................................................................................................................. ........................................ 3.20 V 170° F .................................................................................................................................................. ........................................ 3.02 V 180° F .................................................................................................................................................. ........................................ 2.80 V 190° F .................................................................................................................................................. ........................................ 2.60 V 200° F .................................................................................................................................................. ........................................ 2.40 V Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 477 210° F .................................................................................................................................................. ........................................ 2.20 V 220° F .................................................................................................................................................. ........................................ 2.00 V 230° F .................................................................................................................................................. ........................................ 1.80 V 240° F .................................................................................................................................................. ........................................ 1.62 V 250° F .................................................................................................................................................. ........................................ 1.45 V Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 478 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Crankshaft Position sensor screw .................................................................................................................................................... 12 Nm (105 in lbs) Camshaft Position sensor screw ...................................................................................................................................................... 12 Nm (105 in lbs) Coolant Sensor .......................................................................................................... .......................................................................... 7 Nm (60 in lbs) Ignition Coil .................................... ................................................................................................................................................ 12 Nm (105 in lbs) Ignition Switch ................................................................................................................... ................................................................. 2 Nm (17 in lbs) Spark Plugs ............................................. ........................................................................................................................................... 28 Nm (20 ft lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 479 Coolant Temperature Sensor/Switch (For Computer): Locations Ignition Coil And Coolant Temperature Sensor Location Sensor mounted under ignition coil. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 482 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 483 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 484 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 485 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 486 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 487 Coolant Sensor Circuit Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 488 Coolant Temperature Sensor/Switch (For Computer): Description and Operation LOCATION The Engine Coolant Temperature (ECT) sensor is threaded into the intake manifold, next to the thermostat housing. PURPOSE The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle speed, and ignition spark advance. OPERATION The sensor element extends into the coolant passage, where it maintains constant contact with the engine coolant. The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature increases, sensor resistance decreases.) The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below. As sensor resistance changes, the voltage drop across the sensor changes. The PCM translates the voltage drop across the sensor into engine coolant temperature. THEORY As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor (cold operation), or a 909 ohm resistor (warm operation). The resistance circuits are inside the PCM. For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the 10,000 ohm resistor. When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the 909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 489 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Coolant Temperature Sensor Resistance Test 1. With key off, disconnect connector from coolant temperature sensor. 2. Connect ohmmeter across coolant temperature sensor. Resistance should read as follows; - 700 to 1,000 Ohms at approximately 200°F (operating temperature). - 7,000 to 13,000 ohms at approximately 70°F, (room temperature). 3. If resistance is not within specifications, replace sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 490 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Ignition Coil And Coolant Temperature Sensor Location REMOVAL 1. Drain cooling system until coolant level is below sensor. 2. Disconnect coil pack electrical connector to sensor. 3. Remove coil mounting screws. 4. Rotate coil away from coolant temperature sensor. 5. Disconnect electrical connector from coolant temperature sensor. 6. Remove sensor from engine. INSTALLATION 1. Tighten the coolant sensor to 7 Nm (60 in lbs) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. 4. Install coil. Tighten coil mounting screws to 12 Nm (105 in lbs) torque. 5. Connect electrical connector to coil. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions Temperature Sensor (Gauge): Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 496 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 497 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 498 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 499 Temperature Sensor (Gauge): Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 500 Engine Oil Pressure & Temp. System With Transmission Control Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Page 501 Temperature Sensor (Gauge): Testing and Inspection When a malfunction occurs with a cluster gauge, before disassembling the cluster to check the gauge, check for a defective sending unit or wiring as follows: 1. Ground sending unit connector leads, at the sending unit, in the vehicle. 2. With ignition in ON position, a grounded input will cause the fuel or temperature gauge to read maximum or above. Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Controller/Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection 1. Remove stop lamp switch, then inspect for continuity between terminal No. 5 and No. 6 with plunger released. Continuity Should exist. 2. Inspect for continuity between terminal No. 1 and No. 2 with plunger depressed. Continuity Should exist. 3. Inspect for continuity between terminal No. 3 and No. 4 with plunger depressed. Continuity Should exist. 4. If continuity is not as specified, then stop lamp switch is out of adjustment or defective. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Switch: > 081694 > Apr > 94 > Speed Control Switch - Loose/Rattles Cruise Control Switch: Customer Interest Speed Control Switch - Loose/Rattles NO: 08-16-94 GROUP: Electrical DATE: Apr. 1, 1994 SUBJECT: Speed Control Switch Loose or Rattles MODELS: 1994 (AA) Acclaim/LeBaron Sedan/Spirit (AJ) LeBaron Convertible (AP) Shadow/Sundance (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE STANDARD (NON-LEATHER WRAPPED) STEERING WHEEL, EXCLUDING LONG WHEEL BASE AS-BODY, BUILT PRIOR TO 3/7/94, (MDH 03-07-XX). SYMPTOM/CONDITION: Speed control switch becomes loose or rattles in steering wheel. The most likely cause is cracking of the speed control switch mounting bosses due to lubricant under the paint and on the metal mounting surface of the steering wheel. Additionally, the switch mounting screw holes may be located too far outboard. PARTS REQUIRED: 1 4565265 Speed Control Switch 2 6032986 Screws AR NPN Naphtha Cleaning Solvent (Obtain Locally) REPAIR PROCEDURE: This bulletin involves enlarging the speed control switch mounting holes, cleaning the steering wheel mounting surface, top and bottom, and installing a new speed control switch and mounting screws. 1. Remove the speed control switch from the steering wheel and discard the two mounting screws. NOTE: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE REMOVING THE AIRBAG. FOLLOW ALL WARNINGS IN THE APPROPRIATE SERVICE MANUAL REGARDING AIRBAGS. 2. Remove the steering wheel by removing the airbag module, vibration dampener (if equipped), and speed control wiring as outlined in the appropriate Service Manual. 3. With the steering wheel removed, remove the back cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Switch: > 081694 > Apr > 94 > Speed Control Switch - Loose/Rattles > Page 514 4. Secure the steering wheel in a suitable fixture. Drill out both speed control mounting holes using a 1/4" (6 mm) drill (See Illustration). 5. Using 80 to 180 grit sandpaper, clean the paint off both the top and bottom sides of metal mounting surface. Using a round file or knife, clean out both guide pin holes where the speed control switch mounts (See Illustration). 6. Clean loose debris from the sanded area. Using Naphtha cleaning solvent on a clean rag, thoroughly wipe the sanded area on both sides of the steering wheel. Make sure screw and guide pin holes are also cleaned out with solvent. Allow 2-3 minutes for cleaner to evaporate. NOTE: USE ONLY NAPHTHA CLEANING SOLVENT. ANY OTHER SOLVENT WILL NOT BE EFFECTIVE FOR THIS PROCEDURE. WHEN USING NAPHTHA, FOLLOW ALL MANUFACTURERS WARNINGS AND RECOMMENDATIONS AND AVOID CONTACT WITH PLASTIC SURFACES. 7. Reinstall the steering wheel back cover, steering wheel and all other parts removed in Step 2. 8. Install new speed control switch, P/N 4565265, using two new screws, P/N 6032986. NOTE: THE OLD SPEED CONTROL SWITCH MOUNTING SCREWS MUST NOT BE REUSED, AS THEY MAY BE CONTAMINATED WITH LUBRICANT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-85-30-93 0.5 Hrs. FAILURE CODE: BF - Broken Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > 081694 > Apr > 94 > Speed Control Switch - Loose/Rattles Cruise Control Switch: All Technical Service Bulletins Speed Control Switch - Loose/Rattles NO: 08-16-94 GROUP: Electrical DATE: Apr. 1, 1994 SUBJECT: Speed Control Switch Loose or Rattles MODELS: 1994 (AA) Acclaim/LeBaron Sedan/Spirit (AJ) LeBaron Convertible (AP) Shadow/Sundance (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE STANDARD (NON-LEATHER WRAPPED) STEERING WHEEL, EXCLUDING LONG WHEEL BASE AS-BODY, BUILT PRIOR TO 3/7/94, (MDH 03-07-XX). SYMPTOM/CONDITION: Speed control switch becomes loose or rattles in steering wheel. The most likely cause is cracking of the speed control switch mounting bosses due to lubricant under the paint and on the metal mounting surface of the steering wheel. Additionally, the switch mounting screw holes may be located too far outboard. PARTS REQUIRED: 1 4565265 Speed Control Switch 2 6032986 Screws AR NPN Naphtha Cleaning Solvent (Obtain Locally) REPAIR PROCEDURE: This bulletin involves enlarging the speed control switch mounting holes, cleaning the steering wheel mounting surface, top and bottom, and installing a new speed control switch and mounting screws. 1. Remove the speed control switch from the steering wheel and discard the two mounting screws. NOTE: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE REMOVING THE AIRBAG. FOLLOW ALL WARNINGS IN THE APPROPRIATE SERVICE MANUAL REGARDING AIRBAGS. 2. Remove the steering wheel by removing the airbag module, vibration dampener (if equipped), and speed control wiring as outlined in the appropriate Service Manual. 3. With the steering wheel removed, remove the back cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > 081694 > Apr > 94 > Speed Control Switch - Loose/Rattles > Page 520 4. Secure the steering wheel in a suitable fixture. Drill out both speed control mounting holes using a 1/4" (6 mm) drill (See Illustration). 5. Using 80 to 180 grit sandpaper, clean the paint off both the top and bottom sides of metal mounting surface. Using a round file or knife, clean out both guide pin holes where the speed control switch mounts (See Illustration). 6. Clean loose debris from the sanded area. Using Naphtha cleaning solvent on a clean rag, thoroughly wipe the sanded area on both sides of the steering wheel. Make sure screw and guide pin holes are also cleaned out with solvent. Allow 2-3 minutes for cleaner to evaporate. NOTE: USE ONLY NAPHTHA CLEANING SOLVENT. ANY OTHER SOLVENT WILL NOT BE EFFECTIVE FOR THIS PROCEDURE. WHEN USING NAPHTHA, FOLLOW ALL MANUFACTURERS WARNINGS AND RECOMMENDATIONS AND AVOID CONTACT WITH PLASTIC SURFACES. 7. Reinstall the steering wheel back cover, steering wheel and all other parts removed in Step 2. 8. Install new speed control switch, P/N 4565265, using two new screws, P/N 6032986. NOTE: THE OLD SPEED CONTROL SWITCH MOUNTING SCREWS MUST NOT BE REUSED, AS THEY MAY BE CONTAMINATED WITH LUBRICANT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-85-30-93 0.5 Hrs. FAILURE CODE: BF - Broken Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 521 Cruise Control Switch: Testing and Inspection 1. Disconnect the blade type four wire electrical connector from base of steering column. 2. Using a continuity tester, or an ohmmeter, check for continuity at connector wires. Do not use a test light. Fig. 108 Speed Control Continuity Chart Fig. 8 Speed Control Connector Terminal Identification 3. Results should be obtained according to the chart. If these results are not obtained, replace switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 522 Cruise Control Switch: Service and Repair 1. Disconnect battery ground cable. 2. Turn ignition switch to the Off position. 3. Remove two screws from back of steering wheel. 4. Rock switch away from air bag or horn pad while lifting switch from steering wheel. 5. Disconnect four-way electrical connector. 6. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 531 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 537 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 544 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 545 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 546 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 547 Oil Pressure Sender: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 548 Engine Oil Pressure & Temp. System With Transmission Control Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Locations Air Conditioning Switch: Locations Heater A/C Controls Center Of I/P Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Front End Components Front Of Engine Compartment, Front Of Radiator Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations Engine Compartment Wiring Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Low Pressure Cut-Off Switch Low Pressure Sensor / Switch: Locations Low Pressure Cut-Off Switch The Low pressure cut-out switch (LPCO) is located on the expansion valve. The expansion valve is silver in color. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Low Pressure Cut-Off Switch > Page 564 Low Pressure Sensor / Switch: Locations Low Pressure Cycling Clutch Switch The Electronic Cycling Clutch Switch (ECCS) is located on the A/C expansion valve at the rear of engine compartment. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 565 Low Pressure Sensor / Switch: Description and Operation The Low Pressure Cut-Off (LPCO) Switch monitors the refrigerant gas pressure on the suction side of. the system. The LPCO is located on the expansion valve, and the expansion valve is silver in color. The LPCO turns off voltage to the compressor clutch coil when refrigerant gas pressure drops to levels that could damage the compressor. The LPCO is a sealed factory calibrated unit. It must be replaced if defective. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 566 Low Pressure Sensor / Switch: Testing and Inspection Low Pressure Cut-off Switch The work area temperature must not be below 10°C (50°F) to test the compressor clutch. circuit 1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Raise hood and disconnect LPCO switch connector boot. 3. Using a suitable jumper wire, jump across the terminals inside wire connector boot. 4. If the compressor clutch does not engage, the cycling clutch switch, wiring, relay, or fuse can be defective. 5. If clutch engages, connect manifold gauge set. Read low pressure gauge. At pressure above 97 kPa (14 psi) and above, LPCO switch will complete the clutch circuit. If the low pressure gauge reads below 172 kPa (25 psi), the system is low on refrigerant charge or empty due to a leak. 6. Install connector boot on switch and repeat step number 3. If the clutch does not engage, replace the. LPCO switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Low Pressure Cut-Out Switch Replacement Low Pressure Sensor / Switch: Service and Repair Low Pressure Cut-Out Switch Replacement Low Pressure Cut-Off Switch (LPCO) REMOVAL AND INSTALLATION WARNING: The refrigeration system must be completely empty before proceeding with this operation. 1. Disconnect the boot like wire connector at the cut-off switch. 2. Using a sender unit type socket, remove the switch from the expansion valve. To insure an adequate seal on the switch, use a small amount of thread sealing tape. Reverse the preceding steps. Evacuate and charge the system. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Low Pressure Cut-Out Switch Replacement > Page 569 Low Pressure Sensor / Switch: Service and Repair Low Pressure Cycling Clutch Switch Replacement Electronic Cycling Clutch Switch Combo Valve (ECCS) REMOVAL AND INSTALLATION 1. Disconnect the 3 pin connector at the ECCS. 2. Remove 4 mm hex bolt from side of expansion valve. 3. Slip the capillary tube from the well on the expansion valve. The capillary-tube-well is filled with a special temperature conductive grease. Save this special grease and reuse it when installing the new switch. To install, reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 575 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 576 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 577 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 578 Dimmer Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 579 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly Door Switch: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 588 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly Door Switch: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 594 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Component Locations > Page 597 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 602 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 603 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 604 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 605 Fuel Gauge Sender: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 606 Fuel Pump System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 607 Fuel Gauge Sender: Description and Operation Fuel Pump MODULE And Connector TYPICAL The fuel level sensor is a variable resistor, whose resistance changes as the level of fuel in the tank change. As the level float arm moves, the wiper on the sensor moves along the trace, either closer to or further away from, the sensor signal terminal. The further away the sensor pickup is, the higher the resistance across the sensor is. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 608 Fuel Gauge Sender: Testing and Inspection SENDING UNIT TEST NOTE: When a problem occurs with a cluster gauge -- before disassembling the cluster to check the gauge -- check for a defective sending unit, sending unit wiring, or body control module. Sending units and wiring can be checked by grounding the connector leads at the sending unit. With the ignition ON grounding the the sending unit wire will cause the fuel or temperature gauge to read at or above maximum. (For fuel sending units this is the center terminal of the Fuel pump module connector.) The following procedure tests the resistance of the level sensor. It does not test the sensor circuit. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fluid level changes. 1. To test the level sensor connect an ohmmeter between the sensor signal terminal and the ground terminal of the fuel pump module connector. (The middle terminal and the terminal farthest away from the middle terminal.) 2. Move the float lever to the full position and empty position and note the resistance at both points. 3. Replace the sensor if the resistance is not within the specified values. - Sensor Full Position 8 ohms maximum - Sensor Empty Position 96.5 - 108.0 ohms Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 609 Fuel Gauge Sender: Service and Repair Fuel level sensor replacement procedure is included in Fuel Pump Module service. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 615 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 616 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 617 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 618 Backup Lamp Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Stop Light Switch - Wiring Connector Service Stop Lamp Switch: Technical Service Bulletins Stop Light Switch - Wiring Connector Service NO.: 08-67-93 GROUP: Electrical DATE: Dec. 31, 1993 SUBJECT: Stop Light Switch Wiring Connector Service MODELS: 1995 (PL) Neon 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1994 (AJ) LeBaron Convertible 1994 (AP) Shadow/Sundance 1994 (AS) Caravan/Voyager/Town & Country 1994 (BR) Ram Pickup 1994 (LH) Concorde/Intrepid/Vision 1994 (LH) LHS/New Yorker 1994 (ZJ) Grand Cherokee SYMPTOM/CONDITION: When servicing the stop light switch or wiring connector, the stop light switch wiring connector may be difficult to remove from stop light switch. Attempts to remove the wiring connector may damage the insulator wedge or the switch itself. REPAIR PROCEDURE: This bulletin involves removing the stop light switch with wiring connector attached as an assembly before disconnecting the wiring connector. 1. Remove the stop light switch, with wiring connector still attached to the switch, by turning the switch counterclockwise 1/16 turn and pulling straight out of the mounting bracket. 2. Depress and hold down both locking tabs on the "blue" wiring insulator wedge and pull the wiring connector from the stop light switch insulator, Figure 1. NOTE: DISCONNECTING THE WIRING CONNECTOR HARNESS FROM THE SWITCH BY PULLING ON THE WIRING MAY RESULT IN OPEN CIRCUITS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Stop Light Switch - Wiring Connector Service > Page 623 3. To remove the "blue" wedge insert a small screwdriver between the top of the wiring connector insulator and the wedge and prying up while pushing the wedge out towards the wire harness, Figure 2. 4. To reinstall the wiring harness connector into the stop light switch, reinstall the connector wedge into the connector, then insert the wiring harness connector into the stop light switch assembly and finally install the stop lamp switch assembly into the mounting bracket and secure it by rotating the switch clockwise approximately 1/16 of a turn. If a new stop light switch is being installed, follow the adjustment procedure in the appropriate service manual. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Page 624 Stop Lamp Switch: Locations Brake Switch Sensor mounted on brake pedal support bracket. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions Stop Lamp Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 627 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 628 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 629 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 630 Stop Lamp Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 631 Stop Lamp Switch: Electrical Diagrams Vehicle Speed Control & Stop Lamp Switch SH-57 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 632 Vehicle Speed Control & Stop Lamp Switch SH-58 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Page 633 Stop Lamp Switch: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect stop light switch electrical connector, then remove switch assembly. 3. Reverse procedure to install. If switch adjustment required, proceed as follows: a. Push switch forward until fully seated. This will move brake pedal slightly forward. b. Pull brake pedal back until it will go back no further. Switch will ratchet backward into correct position. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair Combination Switch: Service and Repair The multi-function switch includes the turn signal, headlight beam select and windshield wiper switches. If any of these switches are found defective, the entire multi-function switch must be replaced. 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever. 3. On all models, remove upper and lower steering column covers, then remove multi-function switch tamper proof mounting screws. 4. Pull switch from column and loosen connector screw, then remove connector from switch. Screw remains in connector. 5. Remove switch from the vehicle. 6. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly Door Switch: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly > Page 645 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly Door Switch: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 651 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Switch: > 07-06-98 > Nov > 98 > Cooling Module Fan - Vibrates/Comes Loose Fan Blade: All Technical Service Bulletins Cooling Module Fan - Vibrates/Comes Loose NO: 07-06-98 GROUP: Cooling DATE: Nov. 20, 1998 SUBJECT: Cooling Module Fan Nut MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (International Market) DISCUSSION: Some subject vehicles may experience a loosening or loss of the nut retaining the engine cooling module fan causing a vibration initially. If not addressed promptly, the fan blade will not turn and the engine may overheat. A revised engine cooling module fan retaining nut kit has been released, p/n 05011946AA, to address this condition and should be used for repair any time this condition is experienced and the fan blade is not damaged. The cooling fan blade and motor were balanced as an assembly at the time of manufacture and must be properly oriented to minimize vibration. The cooling fan blade can be installed on the cooling motor shaft in one of two positions. If the cooling fan blade/motor assembly vibrates excessively after replacing the nut, remove and reinstall the cooling fan blade on the motor shaft 180 degrees from the first installation position. The proper torque for the revised fan retaining nut is 6.3-7.3 Nm (55-65 in. lbs.). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 664 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Multi-Function Switch Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions Headlight Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 672 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 673 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 674 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 675 Headlight Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 676 Headlight Switch: Connector Views Headlamp Switch Connector (Part 1 Of 3) Headlamp Switch Connector (Part 2 Of 3) Headlamp Switch Connector (Part 3 Of 3) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 677 Headlight Switch: Electrical Diagrams Headlamp Switch (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 678 Headlamp Switch (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 679 Headlight Switch: Service and Repair The headlamp switch is part of the left pod switch assembly. 1. Fabricate a 3/16 inch diameter metal rod approximately 10 inches long. Bend 1 1/2 inches on both ends 90°. 2. Place fabricated tool in hole right of switch in cluster bezel below the pod switch assembly, then depress lower tab and pull switch free of lower tab. 3. Move tool upward right side of switch to top tab, then pull tab down and pull switch out of bezel. 4. Disconnect wire connector. 5. To install, connect wire connector and push switch into until tabs lock. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams Multi-Function Switch Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 689 Camshaft Position Sensor: Mechanical Specifications Camshaft Position sensor screw ..................................................................................................................................................... 14 Nm (125 in lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor Location The Camshaft Position (CMP) sensor is located on the timing gear cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 692 Camshaft Position Sensor Location Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 695 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 696 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 697 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 698 Camshaft Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 699 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 700 Camshaft Position Sensor: Electrical Diagrams Camshaft Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 701 Camshaft Position Sensor: Description and Operation Camshaft Sensor PURPOSE - Sensor provides PCM with cylinder identification. - PCM uses sensor input to determine fuel injection sequence and ignition timing. OPERATION Sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). - When a notch aligns with the sensor, voltage spikes high (5.0 volts). - As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. - The number of notches determine the amount of pulses. NOTE: If available, an oscilloscope can display the square wave patterns of each timing event. NOTE: The arrows and cylinder call outs on the following image represent which cylinder the flat spot and notches identify, they do not indicate Top Dead Center (TDC) position. Camshaft Sprocket - When the PCM receives two cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder # 1 are next (on driveplate). - When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number # 2 crankshaft timing marks are next. - After 3 camshaft pulses, the PCM knows cylinder # 4 crankshaft timing marks follow. - One camshaft pulse after the three pulses indicates cylinder # 5. - The two camshaft pulses after cylinder 5 signals cylinder # 6. - The PCM can synchronize on cylinders 1 or 4. NOTE: TDC does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. NOTE: The distance between the sensor and camshaft sprocket is critical to system operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE Powertrain Management/Computers and Control Systems/Camshaft Position Sensor/Service and Repair. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 702 Camshaft Position Sensor: Service and Repair Fig. 7 Camshaft Position Sensor REMOVAL 1. Disconnect sensor electrical connector (Fig. 7). 2. Remove engine mount support bracket. 3. Loosen camshaft position sensor retaining bolt enough to allow slot in sensor to slide past the bolt. NOTE: A light tap to top of sensor prior to removal may reduce force needed for removal. 4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on the sensor case, and the O-ring may make removal difficult. INSTALLATION Notes: If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer from the sensor face completely, before attaching new spacer. If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new sensor (Fig. 5). 1. Inspect O-ring for damage, replace if necessary. 2. Ensure the O-ring is positioned in groove of the sensor, and apply a couple drops of clean engine oil to the O-ring prior to installing the sensor (Fig. 7). 3. Install sensor in the chain case cover and push sensor down until contact is made with the camshaft gear. 4. While holding the sensor in this position install and tighten the retaining bolt 14 Nm (125 in-lbs) torque. 5. Connect sensor electrical connector, and position connector away from the accessory belt 6. Install engine mount support bracket. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications NOTE: For information on how this type of sensor operates SEE, Powertrain Management/Computers and Control Systems/Coolant Temperature Sensor/Description and Operation. NOTE: Measure resistance using a high impedance Digital Volt Ohmmeter (DVOM). COLD CURVE (Reference voltage routed to sensor through PCM internal resistance of 10k ohm) Temperature ........................................................................................................................................ ........................................ Voltage -20° F ................................................................................................................................................... ....................................... 4.70 V -10° F ................................................................................................................................................... ....................................... 4.57 V 0° F ...................................................................................................................................................... ...................................... 4.45 V 10° F .................................................................................................................................................... ....................................... 4.30 V 20° F .................................................................................................................................................... ....................................... 4.10 V 30° F .................................................................................................................................................... ....................................... 3.90 V 40° F .................................................................................................................................................... ....................................... 3.60 V 50° F .................................................................................................................................................... ....................................... 3.30 V 60° F .................................................................................................................................................... ....................................... 3.00 V 70° F .................................................................................................................................................... ....................................... 2.75 V 80° F .................................................................................................................................................... ....................................... 2.44 V 90° F .................................................................................................................................................... ....................................... 2.15 V 100° F .................................................................................................................................................. ........................................ 1.83 V 110° F .................................................................................................................................................. ........................................ 1.57 V 120° F .................................................................................................................................................. ........................................ 1.25 V HOT CURVE (Reference voltage routed to sensor through PCM internal resistance of 10 k ohm) Temperature ........................................................................................................................................ ........................................ Voltage 110° F .................................................................................................................................................. ........................................ 4.20 V 120° F .................................................................................................................................................. ........................................ 4.00 V 130° F .................................................................................................................................................. ........................................ 3.77 V 140° F .................................................................................................................................................. ........................................ 3.60 V 150° F .................................................................................................................................................. ........................................ 3.40 V 160° F .................................................................................................................................................. ........................................ 3.20 V 170° F .................................................................................................................................................. ........................................ 3.02 V 180° F .................................................................................................................................................. ........................................ 2.80 V 190° F .................................................................................................................................................. ........................................ 2.60 V 200° F .................................................................................................................................................. ........................................ 2.40 V Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 707 210° F .................................................................................................................................................. ........................................ 2.20 V 220° F .................................................................................................................................................. ........................................ 2.00 V 230° F .................................................................................................................................................. ........................................ 1.80 V 240° F .................................................................................................................................................. ........................................ 1.62 V 250° F .................................................................................................................................................. ........................................ 1.45 V Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 708 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Crankshaft Position sensor screw .................................................................................................................................................... 12 Nm (105 in lbs) Camshaft Position sensor screw ...................................................................................................................................................... 12 Nm (105 in lbs) Coolant Sensor .......................................................................................................... .......................................................................... 7 Nm (60 in lbs) Ignition Coil .................................... ................................................................................................................................................ 12 Nm (105 in lbs) Ignition Switch ................................................................................................................... ................................................................. 2 Nm (17 in lbs) Spark Plugs ............................................. ........................................................................................................................................... 28 Nm (20 ft lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 709 Coolant Temperature Sensor/Switch (For Computer): Locations Ignition Coil And Coolant Temperature Sensor Location Sensor mounted under ignition coil. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 712 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 713 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 714 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 715 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 716 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 717 Coolant Sensor Circuit Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 718 Coolant Temperature Sensor/Switch (For Computer): Description and Operation LOCATION The Engine Coolant Temperature (ECT) sensor is threaded into the intake manifold, next to the thermostat housing. PURPOSE The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle speed, and ignition spark advance. OPERATION The sensor element extends into the coolant passage, where it maintains constant contact with the engine coolant. The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature increases, sensor resistance decreases.) The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below. As sensor resistance changes, the voltage drop across the sensor changes. The PCM translates the voltage drop across the sensor into engine coolant temperature. THEORY As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor (cold operation), or a 909 ohm resistor (warm operation). The resistance circuits are inside the PCM. For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the 10,000 ohm resistor. When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the 909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 719 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Coolant Temperature Sensor Resistance Test 1. With key off, disconnect connector from coolant temperature sensor. 2. Connect ohmmeter across coolant temperature sensor. Resistance should read as follows; - 700 to 1,000 Ohms at approximately 200°F (operating temperature). - 7,000 to 13,000 ohms at approximately 70°F, (room temperature). 3. If resistance is not within specifications, replace sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 720 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Ignition Coil And Coolant Temperature Sensor Location REMOVAL 1. Drain cooling system until coolant level is below sensor. 2. Disconnect coil pack electrical connector to sensor. 3. Remove coil mounting screws. 4. Rotate coil away from coolant temperature sensor. 5. Disconnect electrical connector from coolant temperature sensor. 6. Remove sensor from engine. INSTALLATION 1. Tighten the coolant sensor to 7 Nm (60 in lbs) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. 4. Install coil. Tighten coil mounting screws to 12 Nm (105 in lbs) torque. 5. Connect electrical connector to coil. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 725 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position sensor screw ................................................................................................................................................ 11.9 Nm (105 in lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Crank Position Sensor The Crankshaft Position Sensor is mounted on the transaxle bellhousing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 728 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 731 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 732 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 733 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 734 Crankshaft Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 735 Crankshaft Position Sensor Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 736 Crankshaft Position Sensor: Electrical Diagrams Crankshaft Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 737 Crankshaft Position Sensor: Description and Operation LOCATION Mounted in transmission housing, above distance sensor. PURPOSE Powertrain Control Module (PCM) uses input to determine basic timing. OPERATION Crankshaft Sensor Driveplate Sensor reads a series of slots cut in transmission driveplate. NOTE: The distance between the sensor and torque converter drive plate is critical to system operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE COMPONENT REPLACEMENT AND REPAIR PROCEDURES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 738 Crankshaft Position Sensor: Service and Repair Fig. 5 Crankshaft Position Sensor Removal 1. Disconnect sensor electrical connector (Fig. 5). 2. Remove sensor retaining bolt. 3. Pull sensor straight up, and out of the transaxle housing. Installation Notes: If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer from the sensor face completely, before attaching new spacer. If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new sensor (Fig. 5). 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. 2. While holding the sensor in this position, install and tighten the retaining bolt to 11.9 Nm (105 in-lbs) torque. 3. Connect sensor electrical connector. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications Vacuum in Inches of Mercury MAP sensor Signal Voltage .39 in Hg .............................................................................................................................................. .............................. 4.90 V 3.34 in Hg ............................................................................................................................................ ............................... 4.60 V 6.30 in Hg ............................................................................................................................................ ............................... 3.60 V 9.25 in Hg ............................................................................................................................................ ............................... 3.10 V 12.20 in Hg .......................................................................................................................................... ................................ 2.60 V 15.15 in Hg .......................................................................................................................................... ................................ 2.10 V 18.11 in Hg .......................................................................................................................................... ................................ 1.60 V 21.06 in Hg .......................................................................................................................................... ................................ 1.10 V 24.01 in Hg .......................................................................................................................................... ................................ 0.60 V 26.97 in Hg .......................................................................................................................................... ................................ 0.31 V Condition ............................................................................................................................................. .................................. Expected Output Voltage High Vacuum (Idle/Deceleration) ............................................................................................................................................................. 0.5 to 1.5 volts Medium Vacuum (Cruise/Slight Acceleration) ......................................................................................................................................... 1.5 to 3.0 volts Low Vacuum (Hard Acceleration/Mechanical Failure) ............................................................................................................................. 3.0 to 4.5 volts NOTE: Any reading of 0 volts or over 5 volts indicates a problem in the MAP sensor circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations Manifold Pressure/Vacuum Sensor: Component Locations Engine Control Component Locations Back Side Of Intake Plenum View Sensor mounted on back side of intake plenum. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations > Page 744 Back Side Of Intake Plenum View Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions Manifold Pressure/Vacuum Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 747 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 748 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 749 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 750 Manifold Pressure/Vacuum Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 751 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 752 MAP Sensor Circuit Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 753 Manifold Pressure/Vacuum Sensor: Description and Operation LOCATION Sensor mounted on intake plenum. PURPOSE At start-up, the Powertrain Control Module (PCM) uses sensor to read barometric (atmospheric), pressure, for reference, to calculate air/fuel mixture. During operation the Powertrain Control Module (PCM) monitors sensor input to adjust spark advance and air/fuel mixture. OPERATION PCM supplies 5 volt sensor reference voltage. Sensor, connected to manifold vacuum at throttle body, converts intake manifold pressure into voltage. THEORY Sensor resistance and manifold absolute pressure are inversely proportional (as manifold absolute pressure increases, (low vacuum), sensor resistance decreases and vice versa). OUTPUT VOLTAGES Sensor output voltage range is 0.5 to 4.5 volts. - Output voltages between 0.5 and 1.5 volts indicate a high vacuum situation, such as idle or deceleration. - Output voltages between 1.5 and 3.0 volts indicate a medium level of vacuum such as a cruise or slight acceleration condition. - Output voltages between 3.0 and 4.5 volts indicate a low vacuum situation such as hard acceleration or a mechanical failure. - Any reading of 0 volts or over 5 volts indicates a problem. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 754 Manifold Pressure/Vacuum Sensor: Testing and Inspection NOTE: To perform a complete test of the Manifold Absolute Pressure (MAP) sensor and its circuitry, refer to appropriate Diagnostic Chart. See: Powertrain Management/Computers and Control Systems/Testing and Inspection TO TEST THE MAP SENSOR ONLY: 1. Inspect the rubber nipple (fitting) from the MAP sensor to the throttle body. Repair as necessary. CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 2. Test the MAP sensor output voltage at the MAP sensor connector terminal 2. With the ignition switch ON, and the engine OFF. Output voltage should be 4 to 5 volts. 3. Test the MAP sensor output voltage at the MAP sensor connector terminal 2 at a hot, neutral idle speed condition. The voltage should drop to 1.5 to 2.1 volts. 4. Test PCM (terminal / pin-5) for the same voltage described above to verify the wire harness condition. Repair as necessary. 5. Test MAP sensor supply voltage at sensor connector terminal 3 with the ignition ON. The voltage should be approximately 5 volts (±O.5 V). 5 volts (±0.5 Volts). should also be present at terminal 6 of the PCM wire harness connector. Repair or replace the wire harness as necessary. 6. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM connector terminal / pin-4. Repair the wire harness if necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 755 Manifold Pressure/Vacuum Sensor: Service and Repair MAP" Sensor Removal 1. Disconnect vacuum hose and electrical connector from sensor. 2. Remove sensor mounting screws and remove sensor. Installation 1. Install sensor and tighten screws. 2. Connect vacuum hose and electrical connector from sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Air/Fuel Oxygen Exhaust Ratio Sensor Voltage Gas Content 12.0:1 1.0 Volts [1] 5.0% CO [2] 13.0:1 0.85 Volts 3.8% CO [2] 14.0:1 0.65 Volts 1.3% CO [2] 14.7:1 0.45 Volts [5] 0.1% CO [2] 15.0:1 0.35 Volts 2.0% O2 [3] 16.0:1 0.25 Volts 3.0% O2 [3] 17.0:1 0.10 Volts [4] 4.0% O2 [3] Remarks [1] Full rich condition. [2] CO: Carbon monoxide, is a sign of incomplete ignition, (not enough oxygen to burn all the hydrocarbons in cylinder). [3] O2: Oxygen left over after all hydrocarbons have been burned. [4] Full lean condition. [5] Stoichiometric point: Output voltages below 0.45 volts indicate a lean condition, and output voltages over 0.45 volts indicate a rich condition. NOTE: Both lean and rich conditions are usually accompanied by high Hydrocarbon (HC) readings. Due to not enough fuel, (lean misses), or too much fuel, (not enough oxygen to burn all hydrocarbons). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations EGR Mounting Sensor threaded into exhaust manifold, just above flange. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 761 Back Side Of Intake Plenum View Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 764 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 765 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 766 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 767 Oxygen Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 768 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 769 Oxygen Sensor: Electrical Diagrams Oxygen Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 770 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 771 Oxygen Sensor: Description and Operation O2 Sensor Cutaway View (Typical) SENSOR PURPOSE Powertrain Control Module (PCM) uses input to determine whether to enrich or lean air/fuel mixture, during closed loop operation. SENSOR OPERATION The oxygen sensor generates a varying voltage signal dependent upon exhaust gas oxygen content at that point in the exhaust. - Oxygen sensor voltage signal is produced through a galvanic reaction within the sensors. Using the oxygen sensor voltage signal as an air/fuel ratio indicator the PCM can tell how well the system is responding to its output signals. - Changes in the sensor signal occur because the air/fuel ratio is constantly changing. - When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. - When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. Closed Loop During CLOSED LOOP operation, the PCM monitors the signals it receives from the oxygen sensor, and other sensors, and uses these signals to adjust the injector pulse width according to the current driving condition. Open Loop During OPEN LOOP operation, the PCM ignores the oxygen sensor's signals, and other sensor's signals, and adjusts injector pulse widths according to preprogrammed specifications in the PCM. HEATER PURPOSE Vehicle enters CLOSED LOOP faster, (because sensor reaches operating temperature sooner). Allows CLOSED LOOP operation during extended idle, (because heater maintains correct operating temperature). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test Oxygen Sensor: Testing and Inspection Powertrain Control Module Response Test Oxygen Sensor And Connector NOTE: This test should be performed only after the Oxygen Sensor (O2S) has passed the functional test and heating element test. NOTE: A four gas analyzer is needed to perform this test. NOTE: When performing this test it is important that no part of your body contact the vehicle body, as test results will be inaccurate. CAUTION: NEVER apply voltage directly to any computer sensor wire. PRECONDITIONING AND SET UP 1. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T), (to ensure vehicle and oxygen sensor are at operating temperature and vehicle is in closed loop). 2. Turn engine OFF, disconnect the oxygen sensor connector. Connect a jumper lead to the O2S signal wire. 3. Start the engine and run at 2,500 rpm for 1 minute, with the transmission in PARK (A/T), or NEUTRAL (M/T). 4. Let idle. LEAN MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO ENRICH MIXTURE) 1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery negative, hold for 10 to 20 seconds. - The CO and HC readings should increase, as the PCM opens the injectors for longer periods (longer pulse width), to enrich the mixture. 2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or engine control system will be necessary. SEE DIAGNOSIS BY SYMPTOM. RICH MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO LEAN OUT MIXTURE) 1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery positive, hold for 10 to 20 seconds. - The O2 readings should begin to increase, and the CO reading should decrease. 2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or engine control system will be necessary. SEE DIAGNOSIS BY SYMPTOM. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test > Page 774 Oxygen Sensor: Testing and Inspection Sensor Functional Test Oxygen Sensor And Connector CAUTION: Use a high impedance [1] Digital Volt Ohm Meter (DVOM) ONLY, when testing components on computerized vehicles. 1. Make sure the vehicle is at normal operating temperature. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T). CAUTION: To avoid damaging sensor, voltmeter must be set in Volts mode only, (not ohms). 2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to read DC VOLTS. Disconnect the oxygen sensor ( O2S) electrical connector and connect the positive lead of the DVOM to the oxygen sensor signal wire. 3. Start engine. Create a lean condition for 10 seconds. Voltage should decrease to 0.2 volt or less and remain there. 4. Create a rich condition for 10 seconds. Voltage should increase to 0.8 volt or more and remain there. 5. If sensor fails to vary according to the test steps above, the sensor is defective. 6. Connect sensor and clear codes. Remarks: [1] Minimum 10 Meg (10,000,000) ohm input impedance. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test > Page 775 Oxygen Sensor: Testing and Inspection Sensor Heating Element Test Oxygen Sensor And Connector Oxygen Sensor Connector Identification And PINOUT 1. Disconnect the Heated Oxygen Sensor (O2S), electrical connector from the wiring harness. 2. Set DVOM to read OHMS. Connect the ohmmeter between the heater feed and heater ground (terminals 3 and 4), of the sensor electrical connector. 3. Resistance should be between 5 and 7 ohms, if not replace the sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Page 776 Oxygen Sensor: Service and Repair Oxygen Sensor Location (Typical) Oxygen Sensor Socket WARNING: Avoid physical contact with hot exhaust components. CAUTION: Do not pull on or cut sensor wires, when removing sensor. CAUTION: Use of excessive force may damage threads in exhaust manifold or pipe. REMOVAL 1. Disconnect oxygen sensor electrical connector. 2. Using a suitable tool (Snap-On socket YA8875, or equivalent), carefully remove the sensor from exhaust manifold or pipe. (Slightly tightening the sensor before removal may ease removal.) 3. Clean threads in exhaust manifold with an 18 mm X 1.5 + 6E tap. INSTALLATION 1. If a new sensor is being used, verify that the threads are coated with anti-seize compound, before installing in manifold or pipe. 2. If sensor is being reused, coat sensor threads with a nickel based anti-seize compound, (Loctite 771-64 or equivalent). CAUTION: Do not use graphite or other anti-seize compounds. 3. Install sensor, and tighten to 27 Nm (20 ft-lbs). 4. Connect wiring. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts Throttle Position Sensor: Customer Interest TPS - Harsh, Erratic, Or Delayed Transmission Shifts NO: 18-13-94 Rev. A GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Harsh, Erratic or Delayed Transmission Shifts THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 (AS) Caravan/Voyager/Town & Country 1994 (ES) Chrysler Voyager (Export Only) 1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX). SYMPTOM/CONDITION: Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold soak) and during warm-up. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or III) with the appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full range of travel, full open then full closed, and watch the voltage readings. The voltage change should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic voltage change or no voltage change during throttle movement in encountered, particularly when moving the throttle from wide open to closed throttle, proceed with the following repair.** PARTS REQUIRED: 1 4759001 Throttle Position Sensor REPAIR PROCEDURE: This bulletin involves replacing the throttle position sensor with a revised part. 1. Following the proper procedure, remove and replace the throttle position sensor using the new sensor, P/N 4759001. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-10-95 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts Throttle Position Sensor: All Technical Service Bulletins TPS - Harsh, Erratic, Or Delayed Transmission Shifts NO: 18-13-94 Rev. A GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Harsh, Erratic or Delayed Transmission Shifts THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 (AS) Caravan/Voyager/Town & Country 1994 (ES) Chrysler Voyager (Export Only) 1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX). SYMPTOM/CONDITION: Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold soak) and during warm-up. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or III) with the appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full range of travel, full open then full closed, and watch the voltage readings. The voltage change should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic voltage change or no voltage change during throttle movement in encountered, particularly when moving the throttle from wide open to closed throttle, proceed with the following repair.** PARTS REQUIRED: 1 4759001 Throttle Position Sensor REPAIR PROCEDURE: This bulletin involves replacing the throttle position sensor with a revised part. 1. Following the proper procedure, remove and replace the throttle position sensor using the new sensor, P/N 4759001. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-10-95 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 790 Throttle Position Sensor: Specifications THROTTLE POSITION .................................................................................................................................... INCREASE IN TPS VOLTAGE 10° Closed Throttle* ....................................................................................................................................................... 0 volts 20° ....................................................................................................................................................... ........... 0.38 volts 30° ....................................................................................................................................................... ........... 0.75 volts 45° Half Throttle ........................................................................................................................................................ 1.31 volts 58° ....................................................................................................................................................... ......... 1.80 volts** 75° ....................................................................................................................................................... ........ 2.43 volts*** 90° Wide Open Throttle .................................................................................................................................................. 3.00 volts * At idle position the throttle blade is open 10°. The throttle blade is rotated 80° when the throttle is moved from the idle position to the "wide open" position, . ** The PCM recognizes a TPS voltage rise of 1.80 volts or more over idle position voltage as "Wide Open Throttle" (WOT). *** If the TPS voltage sensed at the PCM rises 2.43 volts or more above idle position voltage, the PCM shuts off fuel injection. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Throttle Body View With Idle Air Control Motor Idle Air Control Motor And Throttle Position Sensor Mounted on throttle body. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 793 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 796 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 797 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 798 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 799 Throttle Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 800 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 801 Throttle Position Sensor: Electrical Diagrams Throttle Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 802 Throttle Position Sensor: Description and Operation PURPOSE PCM uses sensor input with other inputs to determine current operating conditions. PCM adjusts air/fuel mixture (injector pulse width) and ignition timing. OPERATION PCM supplies 5 volt sensor reference voltage. Sensor is a variable resistor (potentiometer), whose resistance is dependent on the angle of the throttle blade (or throttle opening). Output voltage ranges from approximately 0.5 Volts, (at idle position), to approximately 4.0 Volts, (at Wide Open Throttle). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 803 Throttle Position Sensor: Testing and Inspection NOTE: The following procedure tests the TPS only. To perform a complete test of the TPS and its circuitry, SEE Computers and Control Systems/Testing and Inspection/Procedures/Diagnostic Charts/Introduction. PROCEDURE 1. The TPS can be tested with a digital voltmeter. The center terminal of the TPS is the output terminal. 2. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed), and at Wide Open Throttle (WOT). - At idle, TPS output voltage should be approximately 0.5 to 1.0 volt. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. - At wide open throttle, TPS output should be approximately 3.5 volts. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 804 Throttle Position Sensor: Adjustments PROCEDURE - The Throttle Position Sensor on this vehicle is fixed and adjustment is not required. - If sensor output voltage is outside acceptable range, sensor should be replaced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 805 Throttle Position Sensor: Service and Repair Throttle Position Sensor (TPS)/Automatic Idle Speed (AIS) Motor Throttle Position Sensor Removed Removal 1. Disconnect the negative battery cable. 2. Disconnect the Throttle Position Sensor (TPS) wiring connector. 3. Remove the mounting screws (2), and remove the TPS from the throttle shaft. Installation 1. Install the new TPS on the throttle shaft and install screws, torqueing them to 17 in-lbs (2 Nm). 2. Connect the TPS wiring connector. 3. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 814 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 815 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 816 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 822 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 823 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 828 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 829 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 830 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 836 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 837 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 840 Park Neutral Position Switch / PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 841 Transmission Position Switch/Sensor: Locations 4 Speed A/T Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 844 Park / Neutral Position Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 847 Transmission Position Switch/Sensor: Description and Operation Switch, Transmission Range The white Transmission Range Switch (formerly called PRNDL) is used as an input to the Transmission Control Module, on the 4 speed electronic automatic transaxle. Note: The Transmission Range Sensor is a different component from the Transmission Range Switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 850 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 851 Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations Vehicle Speed Sensor: Component Locations This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates vehicle speed based on input received from Input and Output speed sensor mounted on the transaxle. Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 856 Vehicle Speed Sensor: Connector Locations This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates vehicle speed based on input received from Input and Output speed sensor mounted on the transaxle. Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 859 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 860 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 861 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 862 Vehicle Speed Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 863 Vehicle Speed Sensor: Electrical Diagrams Vehicle Speed Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 864 Vehicle Speed Sensor: Description and Operation This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates vehicle speed based on input received from Input and Output speed sensor mounted on the transaxle. Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts Throttle Position Sensor: Customer Interest TPS - Harsh, Erratic, Or Delayed Transmission Shifts NO: 18-13-94 Rev. A GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Harsh, Erratic or Delayed Transmission Shifts THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 (AS) Caravan/Voyager/Town & Country 1994 (ES) Chrysler Voyager (Export Only) 1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX). SYMPTOM/CONDITION: Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold soak) and during warm-up. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or III) with the appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full range of travel, full open then full closed, and watch the voltage readings. The voltage change should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic voltage change or no voltage change during throttle movement in encountered, particularly when moving the throttle from wide open to closed throttle, proceed with the following repair.** PARTS REQUIRED: 1 4759001 Throttle Position Sensor REPAIR PROCEDURE: This bulletin involves replacing the throttle position sensor with a revised part. 1. Following the proper procedure, remove and replace the throttle position sensor using the new sensor, P/N 4759001. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-10-95 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts Throttle Position Sensor: All Technical Service Bulletins TPS - Harsh, Erratic, Or Delayed Transmission Shifts NO: 18-13-94 Rev. A GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Harsh, Erratic or Delayed Transmission Shifts THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 (AS) Caravan/Voyager/Town & Country 1994 (ES) Chrysler Voyager (Export Only) 1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX). SYMPTOM/CONDITION: Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold soak) and during warm-up. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or III) with the appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full range of travel, full open then full closed, and watch the voltage readings. The voltage change should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic voltage change or no voltage change during throttle movement in encountered, particularly when moving the throttle from wide open to closed throttle, proceed with the following repair.** PARTS REQUIRED: 1 4759001 Throttle Position Sensor REPAIR PROCEDURE: This bulletin involves replacing the throttle position sensor with a revised part. 1. Following the proper procedure, remove and replace the throttle position sensor using the new sensor, P/N 4759001. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-10-95 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 879 Throttle Position Sensor: Specifications THROTTLE POSITION .................................................................................................................................... INCREASE IN TPS VOLTAGE 10° Closed Throttle* ....................................................................................................................................................... 0 volts 20° ....................................................................................................................................................... ........... 0.38 volts 30° ....................................................................................................................................................... ........... 0.75 volts 45° Half Throttle ........................................................................................................................................................ 1.31 volts 58° ....................................................................................................................................................... ......... 1.80 volts** 75° ....................................................................................................................................................... ........ 2.43 volts*** 90° Wide Open Throttle .................................................................................................................................................. 3.00 volts * At idle position the throttle blade is open 10°. The throttle blade is rotated 80° when the throttle is moved from the idle position to the "wide open" position, . ** The PCM recognizes a TPS voltage rise of 1.80 volts or more over idle position voltage as "Wide Open Throttle" (WOT). *** If the TPS voltage sensed at the PCM rises 2.43 volts or more above idle position voltage, the PCM shuts off fuel injection. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Throttle Body View With Idle Air Control Motor Idle Air Control Motor And Throttle Position Sensor Mounted on throttle body. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 882 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 885 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 886 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 887 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 888 Throttle Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 889 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 890 Throttle Position Sensor: Electrical Diagrams Throttle Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 891 Throttle Position Sensor: Description and Operation PURPOSE PCM uses sensor input with other inputs to determine current operating conditions. PCM adjusts air/fuel mixture (injector pulse width) and ignition timing. OPERATION PCM supplies 5 volt sensor reference voltage. Sensor is a variable resistor (potentiometer), whose resistance is dependent on the angle of the throttle blade (or throttle opening). Output voltage ranges from approximately 0.5 Volts, (at idle position), to approximately 4.0 Volts, (at Wide Open Throttle). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 892 Throttle Position Sensor: Testing and Inspection NOTE: The following procedure tests the TPS only. To perform a complete test of the TPS and its circuitry, SEE Computers and Control Systems/Testing and Inspection/Procedures/Diagnostic Charts/Introduction. PROCEDURE 1. The TPS can be tested with a digital voltmeter. The center terminal of the TPS is the output terminal. 2. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed), and at Wide Open Throttle (WOT). - At idle, TPS output voltage should be approximately 0.5 to 1.0 volt. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. - At wide open throttle, TPS output should be approximately 3.5 volts. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 893 Throttle Position Sensor: Adjustments PROCEDURE - The Throttle Position Sensor on this vehicle is fixed and adjustment is not required. - If sensor output voltage is outside acceptable range, sensor should be replaced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 894 Throttle Position Sensor: Service and Repair Throttle Position Sensor (TPS)/Automatic Idle Speed (AIS) Motor Throttle Position Sensor Removed Removal 1. Disconnect the negative battery cable. 2. Disconnect the Throttle Position Sensor (TPS) wiring connector. 3. Remove the mounting screws (2), and remove the TPS from the throttle shaft. Installation 1. Install the new TPS on the throttle shaft and install screws, torqueing them to 17 in-lbs (2 Nm). 2. Connect the TPS wiring connector. 3. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 900 Camshaft Position Sensor: Mechanical Specifications Camshaft Position sensor screw ..................................................................................................................................................... 14 Nm (125 in lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor Location The Camshaft Position (CMP) sensor is located on the timing gear cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 903 Camshaft Position Sensor Location Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 906 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 907 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 908 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 909 Camshaft Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 910 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 911 Camshaft Position Sensor: Electrical Diagrams Camshaft Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 912 Camshaft Position Sensor: Description and Operation Camshaft Sensor PURPOSE - Sensor provides PCM with cylinder identification. - PCM uses sensor input to determine fuel injection sequence and ignition timing. OPERATION Sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). - When a notch aligns with the sensor, voltage spikes high (5.0 volts). - As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. - The number of notches determine the amount of pulses. NOTE: If available, an oscilloscope can display the square wave patterns of each timing event. NOTE: The arrows and cylinder call outs on the following image represent which cylinder the flat spot and notches identify, they do not indicate Top Dead Center (TDC) position. Camshaft Sprocket - When the PCM receives two cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder # 1 are next (on driveplate). - When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number # 2 crankshaft timing marks are next. - After 3 camshaft pulses, the PCM knows cylinder # 4 crankshaft timing marks follow. - One camshaft pulse after the three pulses indicates cylinder # 5. - The two camshaft pulses after cylinder 5 signals cylinder # 6. - The PCM can synchronize on cylinders 1 or 4. NOTE: TDC does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. NOTE: The distance between the sensor and camshaft sprocket is critical to system operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE Powertrain Management/Computers and Control Systems/Camshaft Position Sensor/Service and Repair. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 913 Camshaft Position Sensor: Service and Repair Fig. 7 Camshaft Position Sensor REMOVAL 1. Disconnect sensor electrical connector (Fig. 7). 2. Remove engine mount support bracket. 3. Loosen camshaft position sensor retaining bolt enough to allow slot in sensor to slide past the bolt. NOTE: A light tap to top of sensor prior to removal may reduce force needed for removal. 4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on the sensor case, and the O-ring may make removal difficult. INSTALLATION Notes: If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer from the sensor face completely, before attaching new spacer. If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new sensor (Fig. 5). 1. Inspect O-ring for damage, replace if necessary. 2. Ensure the O-ring is positioned in groove of the sensor, and apply a couple drops of clean engine oil to the O-ring prior to installing the sensor (Fig. 7). 3. Install sensor in the chain case cover and push sensor down until contact is made with the camshaft gear. 4. While holding the sensor in this position install and tighten the retaining bolt 14 Nm (125 in-lbs) torque. 5. Connect sensor electrical connector, and position connector away from the accessory belt 6. Install engine mount support bracket. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 918 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position sensor screw ................................................................................................................................................ 11.9 Nm (105 in lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Crank Position Sensor The Crankshaft Position Sensor is mounted on the transaxle bellhousing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 921 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 924 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 925 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 926 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 927 Crankshaft Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 928 Crankshaft Position Sensor Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 929 Crankshaft Position Sensor: Electrical Diagrams Crankshaft Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 930 Crankshaft Position Sensor: Description and Operation LOCATION Mounted in transmission housing, above distance sensor. PURPOSE Powertrain Control Module (PCM) uses input to determine basic timing. OPERATION Crankshaft Sensor Driveplate Sensor reads a series of slots cut in transmission driveplate. NOTE: The distance between the sensor and torque converter drive plate is critical to system operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE COMPONENT REPLACEMENT AND REPAIR PROCEDURES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 931 Crankshaft Position Sensor: Service and Repair Fig. 5 Crankshaft Position Sensor Removal 1. Disconnect sensor electrical connector (Fig. 5). 2. Remove sensor retaining bolt. 3. Pull sensor straight up, and out of the transaxle housing. Installation Notes: If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer from the sensor face completely, before attaching new spacer. If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new sensor (Fig. 5). 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. 2. While holding the sensor in this position, install and tighten the retaining bolt to 11.9 Nm (105 in-lbs) torque. 3. Connect sensor electrical connector. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition - Tamper Resistant Ignition Cylinder Addition NUMBER: 23-44-94D GROUP: Body DATE: Jun. 3, 1994 Models: 1994 Town & Country, Caravan, Voyager - Publication No. 81-370-4105 DISCUSSION: A new method of ignition key cylinder retention is used on the subject vehicles for improved vehicle security. The ignition key cylinder retaining pin has been replaced with a tamper resistant screw and a bracket, refer to the illustration. A Snap-On TTXR20A2 torx-bit or equivalent is required to remove the screw. The 1995 Dakota service manual was completed prior to this information being available to Service Publications. The vehicles listed as 1994 models only, will have this information already in their corresponding 1995 service manual. DESCRIPTION OF CHANGES Add Tamper Resistant Ignition Key Cylinder Info. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 937 8D - 37 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 938 8D - 38 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 939 8D - 39 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 940 8D - 39A Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 946 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 947 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 948 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 949 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 950 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 951 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations Located inside the Airbag Control Module (ACM) which is mounted on a bracket, just forward of. the center console. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information Impact Sensor: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 957 Impact Sensor: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Page 958 Impact Sensor: Description and Operation OPERATION The impact sensor provides verification of the direction and severity of the impact. One impact sensor is used. It is located inside the Airbag Control Module (ACM) which is mounted on a bracket, just forward of. the center console. The impact sensor is an accelerometer that senses deceleration. The deceleration pulses are sent to a microprocessor which contains a decision algorithm. When an impact is severe enough to require airbag protection, the ACM micro processor sends a signal that completes the electrical circuit to the driver and passenger airbags. The sensor is calibrated for the specific vehicle and reacts to the severity and direction of the impact. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Testing and Inspection > Component Tests and General Diagnostics Impact Sensor: Component Tests and General Diagnostics GENERAL INSPECTION A visual inspection consists of physically looking for possible cause of a malfunction. A careful and thorough visual inspection of components may quickly identify malfunction cause and eliminate need for diagnostic testing. If a malfunction is not resolved by visual inspection, proceed with diagnostic testing. 1. On all models, turn ignition switch to On. 2. If air bag warning lamp does not light, proceed with diagnostic testing. 3. If air bag warning lamp fails to go out after ten seconds, proceed with diagnostic testing. 4. Check air bag control module (ACM) case and brackets for dents, cracks or deformities. 5. Check ACM connectors and lock levers for damage and terminals for deformities. 6. Remove air bag module as outlined under Component Service. 7. Never attempt to measure circuit resistance of air bag module even with a specified tester. 8. Check air bag pad cover for dents, cracks or deformities. 9. Check air bag module for dents, cracks or deformities. 10. Check hooks and connectors for damage, terminals for deformities and harness for binds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 961 Impact Sensor: Scan Tool Testing and Procedures Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection Bosch & Nippondenso Starters The clutch pedal switch is a normally open type switch. 1. Locate and disconnect clutch pedal switch connector. 2. Using a suitable continuity tester, check circuit through switch with pedal released, there should be no continuity. 3. With continuity tester still attached, push clutch pedal to floor, tester should show full continuity. 4. Tester should not show continuity until pedal is fully depressed, replace switch if it fails any test. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition - Tamper Resistant Ignition Cylinder Addition NUMBER: 23-44-94D GROUP: Body DATE: Jun. 3, 1994 Models: 1994 Town & Country, Caravan, Voyager - Publication No. 81-370-4105 DISCUSSION: A new method of ignition key cylinder retention is used on the subject vehicles for improved vehicle security. The ignition key cylinder retaining pin has been replaced with a tamper resistant screw and a bracket, refer to the illustration. A Snap-On TTXR20A2 torx-bit or equivalent is required to remove the screw. The 1995 Dakota service manual was completed prior to this information being available to Service Publications. The vehicles listed as 1994 models only, will have this information already in their corresponding 1995 service manual. DESCRIPTION OF CHANGES Add Tamper Resistant Ignition Key Cylinder Info. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 971 8D - 37 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 972 8D - 38 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 973 8D - 39 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 974 8D - 39A Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Customer Interest for Neutral Safety Switch: > 210294 > Feb > 94 > A/T - Engine Stalls On Takeoff Neutral Safety Switch: Customer Interest A/T - Engine Stalls On Takeoff NO: 21-02-94 GROUP: Transmission DATE: Feb. 18, 1994 SUBJECT: Engine Stalls Following Initial Shift From Park Or Neutral To A Forward Gear MODELS: 1991 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1991 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1991 - 1993 (AG) Daytona 1991 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1992 1993 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1993 (AS) Town & Country/Caravan/Voyager 1991 - 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 41TE TRANSMISSIONS. IN ADDITION TO THE VEHICLES LISTED ABOVE, ANY 1989 - 1990 41TE EQUIPPED VEHICLES THAT HAVE HAD A REPLACEMENT CONTROLLER INSTALLED THAT HAS COOLING FINS, OR IS LABELED WITH P/N 4672104, 4672105, 4672209, OR 4713832 ARE ALSO INCLUDED. SYMPTOM/CONDITION: While the temperature of the transmission is -16 F (-27 C) or colder, and the transmission selector lever is placed in any forward gear position, the engine stalls. This can be the result of ice in the neutral/start switch while the Transmission Control Module (TCM) performs the pump prime test when the transmission temperature is -16 F (-27 C) or colder. DIAGNOSIS: Determine if the ambient temperature could have been -16 F (-27 C) or colder when the transmission lever was placed in a forward gear position. Assure the shift selector is not binding and is adjusted correctly. Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB) with appropriate diagnostic procedure manual, verify that all transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707123 Switch, Neutral/Start (Park/Neutral) REPAIR PROCEDURE: NOTE: THE SWITCH SEAL WASHER MUST BE PROPERLY SEATED WHEN TIGHTENING THE SWITCH. FAILURE TO DO SO MAY RESULT IN LEAKAGE OF TRANSMISSION FLUID. This bulletin involves replacing the park/neutral position switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Customer Interest for Neutral Safety Switch: > 210294 > Feb > 94 > A/T - Engine Stalls On Takeoff > Page 983 1. Replace the black park/neutral position switch (P/N 5234319). Torque the new switch to 25 ft.lbs. (34 N-m). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-57-90........0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 210294 > Feb > 94 > A/T - Engine Stalls On Takeoff Neutral Safety Switch: All Technical Service Bulletins A/T - Engine Stalls On Takeoff NO: 21-02-94 GROUP: Transmission DATE: Feb. 18, 1994 SUBJECT: Engine Stalls Following Initial Shift From Park Or Neutral To A Forward Gear MODELS: 1991 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1991 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1991 - 1993 (AG) Daytona 1991 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1992 1993 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1993 (AS) Town & Country/Caravan/Voyager 1991 - 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 41TE TRANSMISSIONS. IN ADDITION TO THE VEHICLES LISTED ABOVE, ANY 1989 - 1990 41TE EQUIPPED VEHICLES THAT HAVE HAD A REPLACEMENT CONTROLLER INSTALLED THAT HAS COOLING FINS, OR IS LABELED WITH P/N 4672104, 4672105, 4672209, OR 4713832 ARE ALSO INCLUDED. SYMPTOM/CONDITION: While the temperature of the transmission is -16 F (-27 C) or colder, and the transmission selector lever is placed in any forward gear position, the engine stalls. This can be the result of ice in the neutral/start switch while the Transmission Control Module (TCM) performs the pump prime test when the transmission temperature is -16 F (-27 C) or colder. DIAGNOSIS: Determine if the ambient temperature could have been -16 F (-27 C) or colder when the transmission lever was placed in a forward gear position. Assure the shift selector is not binding and is adjusted correctly. Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB) with appropriate diagnostic procedure manual, verify that all transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707123 Switch, Neutral/Start (Park/Neutral) REPAIR PROCEDURE: NOTE: THE SWITCH SEAL WASHER MUST BE PROPERLY SEATED WHEN TIGHTENING THE SWITCH. FAILURE TO DO SO MAY RESULT IN LEAKAGE OF TRANSMISSION FLUID. This bulletin involves replacing the park/neutral position switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 210294 > Feb > 94 > A/T - Engine Stalls On Takeoff > Page 989 1. Replace the black park/neutral position switch (P/N 5234319). Torque the new switch to 25 ft.lbs. (34 N-m). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-57-90........0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Page 990 Neutral Safety Switch: Locations Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions Neutral Safety Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 993 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 994 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 995 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 996 Neutral Safety Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Page 997 Neutral Safety Switch: Description and Operation The Neutral Safety Switch sends a signal to the EATX control module and the engine control module, controlling starter relay operation when the transaxle is in any gear other than Park or Neutral. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Page 998 Neutral Safety Switch: Testing and Inspection The 4 speed Automatic Transaxle is computer controlled, if troubleshooting this system, extract codes. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Page 999 Neutral Safety Switch: Service and Repair Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Override Switch <--> [Overdrive Switch, A/T] > Component Information > Locations Overdrive Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Override Switch <--> [Overdrive Switch, A/T] > Component Information > Locations > Page 1005 Overdrive Off Switch (8 - Way) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1017 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1018 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1019 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 1025 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 1026 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1031 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1032 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1033 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 1039 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 1040 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 1043 Park Neutral Position Switch / PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 1044 Transmission Position Switch/Sensor: Locations 4 Speed A/T Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 1047 Park / Neutral Position Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 1050 Transmission Position Switch/Sensor: Description and Operation Switch, Transmission Range The white Transmission Range Switch (formerly called PRNDL) is used as an input to the Transmission Control Module, on the 4 speed electronic automatic transaxle. Note: The Transmission Range Sensor is a different component from the Transmission Range Switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 1053 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 1054 Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 1063 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1068 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1069 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1070 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 1076 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1081 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1082 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1083 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 1084 Input / Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector Input Speed Sensor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector > Page 1087 Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 1088 Transmission Speed Sensor: Description and Operation Three pressure switches incorporated in an assembly with the solenoids identify solenoid application. Two speed sensors read input (torque converter turbine) and output (parking sprag) speeds. Position switch indicates manual shift lever position. Engine speed, throttle position, temperature, etc., are also observed. - Some of these signals are read directly from the engine control sensors; others are read from a multiplex circuit with the powertrain control module. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 1089 Transmission Speed Sensor: Testing and Inspection INPUT (TURBINE) SPEED SENSOR INSPECTION 1. Disconnect the input speed sensor connector. 2. Measure the resistance between the input speed sensor side connector terminals 1 and 2. Standard value: 0.3k - 1.2k ohms 3. If the resistance is outside the standard value, replace the input speed sensor. OUTPUT SPEED SENSOR INSPECTION 1. Disconnect the output speed sensor connector. 2. Measure the resistance between the input speed sensor side connector terminals I and 2. Standard value: 0.3k - 1.2k ohms 3. If the resistance is outside the standard value, replace the output speed sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 1090 Transmission Speed Sensor: Service and Repair CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Input (Turbine) Speed Sensor INPUT The input speed sensor is located to the left of the manual shift lever. CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Output Speed Sensor OUTPUT The output speed sensor is located to the right of the manual shift lever. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1099 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1100 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1101 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1102 Power Window Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1103 Power Window Switch: Electrical Diagrams Overhead Console W/O Mini-Trip Computer (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1104 Overhead Console W/O Mini-Trip Computer (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions Washer Fluid Level Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1110 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1111 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1112 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1113 Washer Fluid Level Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1114 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1115 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair Windshield Washer Switch: Service and Repair The multi-function switch includes the turn signal, headlight beam select and windshield wiper switches. If any of these switches are found defective, the entire multi-function switch must be replaced. 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever. 3. On all models, remove upper and lower steering column covers, then remove multi-function switch tamper proof mounting screws. 4. Pull switch from column and loosen connector screw, then remove connector from switch. Screw remains in connector. 5. Remove switch from the vehicle. 6. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Wiper Switch: Diagrams Multi-Function Switch Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1122 Rear Wiper Switch Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1123 Wiper Switch: Testing and Inspection 1. Place pod switch in the Off position. Intermittent Wiper Pod Switch 2. Check for continuity between terminals A6 and A4. If continuity is not indicated, replace switch. 3. Place pod switch in the Max Delay position (left end of variable resistor). 4. Check for continuity between terminal A7 and terminals A5, A3 and B3. If continuity is not indicated, replace pod switch. 5. Check resistance between terminals A1 and B3. Resistance should measure 210,000-390,000 ohms. If not, replace the pod switch. 6. Place switch in the Min Delay position (right end of variable resistor). 7. Check for continuity between terminal A7 and terminals A5, A3 and B3. 8. Check resistance between terminals A1 and B3. Resistance should measure 350-650 ohms. 9. When the slide is moved from Max to Min Delay, or opposite. Continuity between terminal A7 and terminals A5, A3 and B3 should remain constant. If not, replace switch. 10. Resistance between terminals A1 and B3 will decrease as the control is moved from Max to Min Delay, or increase when moved from Min to Max Delay. If not, replace switch. 11. Place switch in the Lo position, then check for continuity between terminals A4 and B3. If continuity is not indicated, replace pod switch. 12. Place switch in Hi position, then check for continuity between terminals A2 and B3. If continuity is not indicated, replace switch. 13. Check for continuity between terminals B3 and B4, when the front washer button is depressed. If not, replace switch. 14. Check for continuity between terminals B2 and B5 when the rear wiper switch is in the On position (indicator lamp will illuminate only when the headlamps are on). If continuity is not indicated, replace switch. 15. Check continuity between terminals B1 and B5 when the rear washer button is depressed. If continuity is not indicated, replace the switch. 16. Two switch illuminating bulbs are fed by terminal B5 (ground) and B6 (power). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Alignment Specifications Alignment: Specifications Front Alignment Specifications Caster, Degrees .................................................................................................................................. .................................................................... +1.3 [01] Camber, Degrees ............................................ .............................................................................................................................................................. .... 0.3 Toe-In, Inch .............................................................................................................................. ..................................................................................... 1/16 Ball Joint Wear ...................................... .............................................................................................................................................................. ........... [03] [01] -- Reference angle only, not adjustable. [03] -- Refer to Ball Joint Inspection in Front Steering & Suspension section. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Alignment Specifications > Page 1129 Alignment: Specifications Rear Alignment Specifications Caster, Degrees .................................................................................................................................. .................................................................................. -- Camber, Degrees .......................................... .............................................................................................................................................................. ...... -0.2 Toe-In, Inch ........................................................................................................................... ....................................................................................... 0 [01] Ball Joint Wear .................................. .............................................................................................................................................................. ................ [04] [01] -- Toe-out when vehicle is backed onto alignment rack is toe-in when driving. [04] -- Refer to Ball Joint Inspection in Rear Steering & Suspension section. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment Alignment: Service and Repair Front Alignment Adjustment CASTER The caster angle on these vehicles cannot be adjusted. Fig. 1 Camber Adjustment CAMBER To adjust camber, loosen cam and through bolts. Rotate upper cam bolt to move top of wheel in or out to achieve specified camber angle. Torque cam bolt nut to 75 ft. lbs. plus an additional 1/4 turn. Fig. 2 Toe-in Adjustment TOE-IN Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment > Page 1132 To adjust toe-in, center steering wheel and hold in position with a suitable tool. Loosen tie rod locknuts and rotate rod to adjust toe-in to specifications. Use care not to twist steering gear rubber boots. Torque tie rod locknuts to 55 ft. lbs. Adjust position of steering gear rubber boots. Remove steering wheel holding tool. Preliminary Inspection 1. Tires are at recommended pressure, are of equal size and have approximately the same wear pattern 2. Check front wheel and tire assembly for radial runout and inspect lower ball joints and steering linkage for looseness. 3. Check front and rear springs for sagging or damage. 4. Front suspension inspections should be performed on a level floor or alignment rack with fuel tank at capacity, and vehicle free of luggage and passenger compartment load. 5. Prior to each alignment reading, vehicle should be bounced an equal number of times from center of the bumper alternating first from rear, then front, and releasing at bottom of down cycle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment > Page 1133 Alignment: Service and Repair Rear Alignment FWD MODELS Fig. 3 Shim Installation For Toe-out (FWD) Fig. 4 Shim Installation For Toe-in (FWD) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment > Page 1134 Fig. 5 Shim Installation For Positive Camber (FWD) Fig. 6 Shim Installation For Negative Camber (FWD) Alignment adjustment is made by adding .010 inch shims between spindle mounting surface and axle casting. Each shim equals wheel change by 0.3.° When recording rear toe-in (vehicle backed onto alignment rack) remember to reverse sign convention. Install alignment shims as follows; 1. Raise and support vehicle, then remove wheel. 2. Remove brake drum, then loosen four brake assembly and spindle mounting bolts enough to allow clearance for shim installation. Do not remove mounting bolts. 3. Install shims as shown. No more than 2 shims on each spindle should be used to bring alignment within acceptable range. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations Fig 1 Intake Plenum Mounting Bolts Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications Air/Fuel Mixture: Specifications The Air/Fuel Ratio is controlled by the Powertrain Control Module (PCM) and is not adjustable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications > Page 1143 Air/Fuel Mixture: Adjustments CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle mixture using this screw! Idle mixture is electronically controlled by the Powertrain Control Module (PCM), and is not adjustable. If an idle mixture problem is suspected, check oxygen sensor and feedback system. SEE Computers and Control Systems. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications NOTE: Idle speed is not adjustable. Powertrain Control Module (PCM) controls idle speed through Idle Air Control (IAC) Motor. If idle speed is outside of specifications, or is rough, or unstable, inspect and clean throttle body, (if deposits are visible). After cleaning throttle body perform minimum air flow test. SEE DIAGNOSIS, TESTING AND INSPECTION PROCEDURES MINIMUM AIRFLOW TEST IDLE SPEED ODOMETER READING IDLE SPEED Less than 1000 miles 525-875 RPM More than 1000 miles 575-875 RPM Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1147 Idle Speed: Adjustments CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle speed using this screw, unless directed to do so in a service procedure. Idle speed is electronically controlled by the Powertrain Control Module (PCM) through the Idle Air Control (IAC) motor, and is not adjustable. If idle is outside of specified RPM, or is rough, or unstable, inspect and clean throttle body if deposits are visible. Perform Minimum Idle Air Flow Test if applicable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fig 1 Intake Plenum Mounting Bolts Fuel Pressure Release Procedure - Typical WARNING: The fuel system is under constant pressure of approximately 48 psi (330 kPa), even when the engine is OFF. 1. Disconnect negative battery cable. 2. Loosen fuel tank filler cap to relieve fuel tank pressure. 3. Remove cap on fuel rail pressure test port (Fig. 1). 4. Place one end of fuel pressure release hose, tool C-4799-1 (or equivalent), in an approved gasoline container. Connect the other end of this hose to the fuel rail service port. Fuel pressure should bleed off into container. 5. Perform necessary fuel system service procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications 3.3L, 3.8L Except Code T Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations 3.3L, 3.8L Except Code T Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations This vehicle is not equipped with timing marks. However spark advance can be monitored using a DRBII or equivalent scan tool. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Ignition Cable: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 1170 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 1171 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec > 94 > A/T Harsh Shift At Low Speed/Speedo. Fluctuates Ignition Cable: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec > 94 > A/T Harsh Shift At Low Speed/Speedo. Fluctuates > Page 1177 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec > 94 > A/T Harsh Shift At Low Speed/Speedo. Fluctuates > Page 1178 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1179 Ignition Cable: Specifications Minimum ..................................................................................................................................................... 250 ohms per inch (3,000 ohms per foot) Maximum ............................................................................................................................................... 1,000 ohms per inch (12,000 ohms per foot) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1180 Ignition Cable: Description and Operation NOTE: Spark Plug cables are sometimes referred to as "secondary ignition wires". Purpose Transfer electrical current from the distributor to individual spark plugs at each cylinder. Resistance type cables are used to suppress Radio Frequency Interference (RFI), from the ignition system. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Ignition Cable: Initial Inspection and Diagnostic Overview INSPECTION Check the high-tension cable connections for good contact at the ignition coil, distributor cap towers and spark plugs. Terminals should be fully seated. The terminals and covers should be in good condition. Terminals should fit tightly to the ignition coil, distributor cap, and spark plugs. The cover (boot) of the cable should fit tight at the coil tower, distributor tower or spark plug insulator. NOTE: Loose cable connections can cause corrosion and increase resistance resulting in shorter cable service life. To maintain proper sealing at terminal connections, do not disconnect cables. This should only be done when testing. Clean high tension cables with a cloth moistened with a nonflammable solvent and wipe dry. Check for brittle or cracked insulation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1183 Ignition Cable: Component Tests and General Diagnostics Secondary Ignition Cable Insulation Test CAUTION: Do not pull spark plug cables from distributor cap of four cylinder engines. The cables must be released from inside the distributor cap. CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during testing. Excessive heat could damage the catalytic converter. Total test time must not exceed ten minutes. CAUTION: To maintain proper sealing at the terminal connections, the connections should not be broken unless testing indicates high resistance, an open circuit or other damage. INSPECTION Check connections at the coil, distributor cap towers and spark plugs. Terminals should be fully seated, and the nipples and spark plug covers should be in good condition. Covers should fit tightly on the coil, distributor cap towers and spark plug insulators. Cable connections that are loose will corrode and increase the resistance and permit water to enter the towers causing ignition malfunction. INSULATION TEST NOTE: When testing secondary cables for punctures and cracks with an oscilloscope follow the equipment manufacturers instructions. If an oscilloscope is not available, secondary cables can be tested as follows: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. 2. With engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. Check the coil cable the same way. 3. Replace ALL cracked, leaking or faulty cables. RESISTANCE TEST Use an ohmmeter to check resistance type cable for open circuits, loose terminals or high resistance as follows: Remove cable from spark plug. Lift distributor cap from distributor with cables intact. Do not remove cables from cap. The cables must be removed from the spark plugs. Connect the ohmmeter between spark plug end terminal and the corresponding electrode inside the cap, make sure ohmmeter probes arc in good contact. Resistance should be within tolerance shown in the cable resistance chart. If resistance is not within tolerance, remove cable at cap tower and check the cable. If resistance is still not within tolerance, replace cable assembly. Test all spark plug cables in same manner. To test coil to distributor cap high tension cable, remove distributor cap with the cable intact. Do not remove cable from the cap. Connect the ohmmeter between center contact in the cap and remove the cable at coil tower and check cable resistance. If resistance is not within tolerance, replace the cable. Also, check for a loose connection at the tower or for a faulty coil. Inspect coil tower for cracks or carbon tracking. Secondary Ignition Cable Resistance Test CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during testing. Excessive heat could damage the catalytic converter. Total test time must not exceed ten minutes. CAUTION: To maintain proper sealing at the terminal connections, the connections should not be broken unless testing indicates high resistance, an open circuit or other damage. NOTE: Use an ohmmeter to check resistance type cable for open circuits, loose terminals or high resistance as follows: SPARK PLUG CABLES 1. Remove cable from spark plug. 2. Lift distributor cap from distributor with cables intact. Do not remove cables from cap. The cables must be removed from the spark plugs. 3. Connect the ohmmeter between spark plug end terminal and the corresponding electrode inside the cap, ensure probes make good contact. Resistance should be within tolerance. 4. If the resistance is not within tolerance, remove cable at cap tower and check the cable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1184 5. If resistance is still not within tolerance, replace cable assembly. 6. Test all spark plug cables in same manner. COIL TO DISTRIBUTOR HIGH TENSION CABLE 1. Remove distributor cap with the cable intact. Do not remove cable from the cap. 2. Remove the cable at coil tower 3. Connect the ohmmeter between center contact in the cap and the coil end of cable. 4. If resistance is not within tolerance, replace the cable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications Spark Plug: Specifications Gap Specifications NOTE: Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Spark Plug Gap ................................................................................................................................... ............................... 1.2 to 1.3 mm (0.048 to 0.053 in) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications > Page 1189 Spark Plug: Specifications Tightening Specifications Spark Plug Torque ............................................................................................................................... ....................................................... 28 Nm (20 ft-lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1190 Spark Plug: Description and Operation Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for spark plug diagnosis. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator NOTE: Replace any spark plugs which have cracked broken or chipped insulators. Symptoms: Insulator chipped or broken. Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap. - Severe detonation also can separate the insulator from the center electrode. - Sudden Rise In Tip Temperature. - Severe Operating Conditions. - Improper Gapping Of Plugs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1193 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1194 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Symptoms: Dry, black deposits on the electrodes. Possible Causes: - On one or two plugs, may be caused by sticking valves or defective spark plug cables. - On the entire set, may be caused by a clogged air cleaner. - Poor Ignition Output NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs do not reach a high enough operating temperature during short operating periods to burn fuel completely. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1195 Spark Plug: Testing and Inspection Electrode Gap Bridging Electrode Gap Bridging Symptoms: Gap between the electrodes bridged by deposits. Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the electrodes. NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1196 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator NOTE: Replace any spark plugs which have cracked broken or chipped insulators. Symptoms: Insulator chipped or broken. Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap. - Severe detonation also can separate the insulator from the center electrode. - Sudden Rise In Tip Temperature. - Severe Operating Conditions. - Improper Gapping Of Plugs. Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Symptoms: Dry, black deposits on the electrodes. Possible Causes: - On one or two plugs, may be caused by sticking valves or defective spark plug cables. - On the entire set, may be caused by a clogged air cleaner. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1197 - Poor Ignition Output NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs do not reach a high enough operating temperature during short operating periods to burn fuel completely. Electrode Gap Bridging Electrode Gap Bridging Symptoms: Gap between the electrodes bridged by deposits. Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the electrodes. NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures. Heavy Colored Deposits DESCRIPTION: Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on the side facing the intake valve. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap, and reinstall .............................................................................................................................................................. .................................................................................... Oil or Ash Encrusted Oil Or Ash Encrusted Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1198 Symptoms: Electrodes encrusted with dry oil or ash. Possible Causes: One or more plugs, evaluate the cause of oil entry into the combustion chamber. Premature Electrode Wear - Preignition Damage Preignition Damage Symptoms: Center electrode dissolves first and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Possible Causes: Excessive combustion chamber temperature. - Incorrect spark plug heat range [1]. - Ignition timing is over advanced - Other operating conditions are causing engine overheating. [1] Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Red, Brown, Yellow or White Deposits - Fuel Additives Scavenger Deposits Symptoms: Red, Brown, White or Yellow deposits. Possible Causes: Normal condition caused by certain fuel additives which are designed to change the nature of deposits and decrease spark plug misfire tendencies. NOTE: Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and be cleaned using standard procedures. Shiny Yellow Glaze DESCRIPTION: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1199 Shiny yellow glaze coating on the insulator. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Metal By-products Of Combustion - Avoid sudden acceleration with wide open throttle after long periods of low speed driving. .............................................................................................................................................................. .................................................................................... Spark Plug Inspection PROCEDURE - Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance Schedules. - Spark plugs that have low mileage may be cleaned and reused if not otherwise defective. Refer to the Spark Plug Condition of this section. After cleaning, file the center electrode flat with a small point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The spark plug gap is 0.89 mm (0.035 in). - Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Spark Plug Resistance Test Resistance should be at least 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Wet Oily Deposits Symptoms: Electrodes coated with excessive wet fuel or oil. Possible Causes: In older engines, wet fouling can be caused by worn rings or excessive cylinder wear. - In new or recently overhauled engines, fouling may occur before normal oil control is achieved. Break-in fouled spark plugs can be usually be cleaned and installed. White or Gray - Burned or Blistered Insulator Spark Plug Overheating Symptoms: White or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in per 1000 miles of operation. Possible Causes: Plug(s) with wrong heat range. - Over advanced ignition timing. - Detonation - Cooling system malfunction - Check for lean air-fuel mixture - Check the torque value of the plugs to ensure good plug-engine seat contact Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1200 Spark Plug: Adjustments Setting Spark Plug Electrode Gap Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground -- center electrode. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Replacement Notes Spark Plug: Service and Repair Replacement Notes TIP: Always keep plugs in the order they were removed. Any plug that looks different from other plugs indicates a problem in that cylinder. NOTE: For further diagnosis by spark plug condition SEE Ignition System/Spark Plug/Testing and Inspection/Procedures Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Replacement Notes > Page 1203 Spark Plug: Service and Repair Removal and Installation CAUTION: Note routing of secondary ignition cables before removing. Failure to route cables properly may result in radio interference, ignition cross fire, or ignition short to ground. NOTE: Keep plugs in order removed. A plug, that looks different from the rest, could be a problem indicator. REMOVAL 1. Spray compressed air around spark plug to prevent foreign material from entering combustion chamber. 2. Remove spark plug wire by grasping boot and turning 1/2 turn while pulling boot back in a steady motion. 3. Remove spark plug using socket with foam insert. INSPECT FOR: - Color of Deposits - Excessive Deposits - Electrode wear - Cracked or Damaged Threads Or Insulator - Worn or Bent Electrodes - Damaged Gasket INSTALLATION 1. Start plug in cylinder head by hand, to prevent cross threading. CAUTION: Do not overtighten plugs, overtightening can distort plugs resulting in a changed gap. 2. Torque spark plugs to 20 ft-lbs (28 Nm). 3. Install secondary ignition cables on spark plugs, (be sure connectors are pushed onto plug completely). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Cylinder Compression Pressure 100 psi NOTE: No more than 25% variance between cylinders. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1207 Compression Check: Service Precautions COMPRESSION TESTING When performing a compression test, remove the fuel pump relay fuse and disconnect power to the ignition. This will stop fuel flow to the injectors and prevent engine from starting. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1208 Compression Check: Testing and Inspection PROCEDURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire (Conventional Ignition System). For Direct Ignition System (DIS) disconnect the coil connector. 5 . Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adaptor into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is reached on gage. Record this pressure as #1 cylinder pressure. 7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 9. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. 11. Clean or replace spark plugs as necessary and adjust gap. Tighten to specifications. 12. Test resistance of spark plug cables. Perform secondary circuit inspection. 13. Test coil output voltage, primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at idle and different RPM ranges. 15. The air filter elements should be replaced as specified. 16. Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt drives. 18. Road test vehicle as a final test. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments This engine uses hydraulic lash adjusters, no adjustment is necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 070294A > Dec > 94 > Serpentine Drive Belt - Comes Off Pulleys Drive Belt: Customer Interest Serpentine Drive Belt - Comes Off Pulleys NO.: 07-02-94 Rev. A GROUP: Cooling DATE: Dec. 23, 1994 SUBJECT: Serpentine Drive Belt Comes Off Pulleys NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-02-94, DATED MAR. 4, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ADD 1995 AND ES VEHICLES AND ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1991 - **1995** (AS) Town & Country/Caravan/Voyager **1992 - 1995 (ES) Chrysler Voyager (European Market)** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: If the vehicle is driven through deep or drifted snow the serpentine drive belt may be forced off of its pulleys by snow coming in between the belt and the pulleys. DIAGNOSIS: Determine the road conditions the driver of the vehicle was encountering at the time the serpentine belt came off. Verify all of the pulleys are in proper alignment and pulleys and accessories are properly attached. If the driver of the vehicle indicates deep or drifted snow may have been a factor in the serpentine belt coming off its pulleys and any pulley mis-alignment and/or accessory/pulley attachment problem has been corrected, perform the following repair procedure. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves attaching a shield to the power steering pump and the power steering pump bracket that prevents snow from coming in between the serpentine belt and the power steering pump pulley. 1. Re-install the serpentine drive belt or replace with a new belt if damaged. 2. Remove the second from the bottom bolt that attaches the power steering pump bracket to the engine block. NOTE: ON EARLY BUILT 1991 MODEL VEHICLES, IF THERE IS A TAB ON THE POWER STEERING BRACKET THAT INTERFERES WITH THE FIT OF THE SHIELD, IT IS NECESSARY TO SAW IT OFF. DO NOT BREAK THE TAB OFF. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 070294A > Dec > 94 > Serpentine Drive Belt - Comes Off Pulleys > Page 1220 3. Position the shield (P/N 4773892) so its mounting hole (closest to the oval cutout of the shield) goes over the stud on the back of the power steering pump and the other mounting hole is aligned with the hole of power steering pump bracket from which the bolt was removed in step 2. 4. Install the lower power steering pump bracket attaching bolt and torque to 30 - 50 ft.lbs. (40.7 67.8 N-m). 5. Install nut/washer (P/N 6501926) on the stud at the back of the power steering pump and torque to 30 - 50 ft.lbs. (40.7 - 67.8 N-m). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 07-20-15-95 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 070294A > Dec > 94 > Serpentine Drive Belt - Comes Off Pulleys Drive Belt: All Technical Service Bulletins Serpentine Drive Belt - Comes Off Pulleys NO.: 07-02-94 Rev. A GROUP: Cooling DATE: Dec. 23, 1994 SUBJECT: Serpentine Drive Belt Comes Off Pulleys NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-02-94, DATED MAR. 4, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ADD 1995 AND ES VEHICLES AND ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1991 - **1995** (AS) Town & Country/Caravan/Voyager **1992 - 1995 (ES) Chrysler Voyager (European Market)** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: If the vehicle is driven through deep or drifted snow the serpentine drive belt may be forced off of its pulleys by snow coming in between the belt and the pulleys. DIAGNOSIS: Determine the road conditions the driver of the vehicle was encountering at the time the serpentine belt came off. Verify all of the pulleys are in proper alignment and pulleys and accessories are properly attached. If the driver of the vehicle indicates deep or drifted snow may have been a factor in the serpentine belt coming off its pulleys and any pulley mis-alignment and/or accessory/pulley attachment problem has been corrected, perform the following repair procedure. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves attaching a shield to the power steering pump and the power steering pump bracket that prevents snow from coming in between the serpentine belt and the power steering pump pulley. 1. Re-install the serpentine drive belt or replace with a new belt if damaged. 2. Remove the second from the bottom bolt that attaches the power steering pump bracket to the engine block. NOTE: ON EARLY BUILT 1991 MODEL VEHICLES, IF THERE IS A TAB ON THE POWER STEERING BRACKET THAT INTERFERES WITH THE FIT OF THE SHIELD, IT IS NECESSARY TO SAW IT OFF. DO NOT BREAK THE TAB OFF. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 070294A > Dec > 94 > Serpentine Drive Belt - Comes Off Pulleys > Page 1226 3. Position the shield (P/N 4773892) so its mounting hole (closest to the oval cutout of the shield) goes over the stud on the back of the power steering pump and the other mounting hole is aligned with the hole of power steering pump bracket from which the bolt was removed in step 2. 4. Install the lower power steering pump bracket attaching bolt and torque to 30 - 50 ft.lbs. (40.7 67.8 N-m). 5. Install nut/washer (P/N 6501926) on the stud at the back of the power steering pump and torque to 30 - 50 ft.lbs. (40.7 - 67.8 N-m). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 07-20-15-95 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1227 Drive Belt: Specifications Belt tension is controlled automatically by the dynamic tensioner. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > With A/C Fig. 34 Serpentine Drive Belt Routing Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > With A/C > Page 1230 Drive Belt: Diagrams Without A/C Fig. 34 Serpentine Drive Belt Routing This image shows an air conditioning compressor. The OE does not provide an image for accessory belt routing without A/C. This article is included here to provide the accessory drive belt routing for a non-air conditioned vehicle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1231 Drive Belt: Description and Operation The accessory drive system utilizes two different style of drive belts. The conventional V-belt and the Poly-v belt are used to drive the generator, air conditioning compressor, power steering pump and water pump. Satisfactory performance of these belts depends on belt condition and proper belt tension. Belt tensioning should be performed with the aid of a Burroughs gauge special tool C-4162, or equivalent. Because of space limitations in the engine compartment, the use of the gauge may be restricted. Raise the vehicle on a hoist and then remove the splash shield to gain access to the drive belts. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1232 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1233 Drive Belt: Adjustments PROPER BELT TENSION Satisfactory performance of the belt driven accessories depends on proper belt tension. Belt tensioning should be performed with the aid of a Burroughs gauge Special Tool C-4162. Because of space limitations in the engine compartment, the use of the gauge may be restricted. Raise the vehicle on a hoist and the remove the splash shield to gain access to the drive belts. BELT TENSION GAUGE METHOD Use belt tensioning Special Tool Kit C-4162 for: CAUTION: The Burroughs gauge for the Poly-V belt is not to be used on the V-belt. These gauges are not interchangeable. For Conventional V-belts - affix the Burroughs gauge (Special Tool C-4162) to the belt. Adjust the belt tension for New or Used belt as prescribed in specifications. For a Poly-V Belt - affix the Poly-V Burroughs gauge to the belt and then apply specified tension to the belt as prescribed in specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and Installation Drive Belt: Service and Repair Removal and Installation Fig. 6 Accessory Drive Belt REMOVE/INSTALL The Poly-V Drive belt is provided with a dynamic tensioner Fig. 6 to maintain proper belt tension. To remove or install this belt: 1. Raise vehicle on hoist. 2. Remove right front splash shield. 3. Release tension by rotating the tensioner clockwise Fig. 6. 4. Reverse above procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1236 Drive Belt: Service and Repair Cleaning and Inspection When inspecting serpentine drive belts, small cracks that run across the ribbed surface of the belt from rib to rib, are considered normal. These are not reasons to replace the belt. However, cracks running along the rib (not across) are not normal. Any belt with cracks running along the rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Page 1237 Belt Tension Gauge C-4162 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature Fluid Filter - A/T: Customer Interest A/T - Slips In Reverse At Low Temperature NO: 21-06-96 GROUP: Transmission DATE: Apr. 26, 1996 SUBJECT: Slips In Reverse At Low Temperature MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX). SYMPTOM/CONDITION: Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these temperature/time conditions is considered normal. DIAGNOSIS: If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If the transaxle also slips going into Drive, further diagnosis is required. PARTS REQUIRED: 1 4659837 Piston, Low/Reverse Servo AR 4318025 Sealant, RTV AR 4467721 Fluid, Mopar Automatic Transmission Type 7176 1 4269649 Filter, Transaxle 1 4269671 Gasket, Transaxle Filter REPAIR PROCEDURE: This bulletin involves installing a revised Low/Reverse servo piston. 1. Raise the vehicle with an appropriate hoist. 2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam. 3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside the oil pan and magnet. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1247 4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the transaxle oil filter and gasket from the valve body and discard (refer to Figure 1). 5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to Figure 2). 6. Remove the neutral start/back-up lamp switch (refer to Figure 3). 7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes from the transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1248 8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse servo (refer to Figures 5, 6 and 7). 9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo assembly. 10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs. (4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm). 11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs. (12 Nm). 12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm). 13. Attach the parking rod to the valve body with the parking rod E-clip. 14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the 2 attaching screws to 40 in. lbs. (5 Nm). 15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to 165 in. lbs. (19 Nm). 16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. 17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. 18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the ADD mark on dipstick. 19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1249 Labor Operation No: 21-80-10-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-05-97 > Mar > 97 > A/T - 41TE/42LE Shudder During EMCC Shift Technical Service Bulletin # 21-05-97 Date: 970314 A/T - 41TE/42LE Shudder During EMCC Shift NO: 21-05-97 GROUP: Transmission DATE: Mar. 14, 1997 SUBJECT: 41TE/42LE Transaxle Shudder During an EMCC (Electronically Modulated Converter Clutch) Shift MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: 1989 TO 1995 MODELS SHOULD HAVE TSB 18-24-95 PERFORMED PRIOR TO PROCEEDING WITH THIS REPAIR PROCEDURE. SYMPTOM/CONDITION: Transaxle shudder during a 3rd gear to 3rd gear partial EMCC (Electronically Modulated Converter Clutch) engagement, 3rd gear partial EMCC to 4th gear partial EMCC engagement, or 4th gear to 4th gear EMCC engagement. Vehicle speed will be above 40 mph to obtain these shift points. This condition can be the result of worn out automatic transaxle fluid, using additives in the transaxle fluid, or from using the wrong type fluid (Dexron II, III, or Mercon) in the transaxle. NOTE: MOPAR ATF+2 TYPE 7176 IS THE ONLY RECOMMENDED FLUID FOR THESE TRANSAXLES. DIAGNOSIS: Bring the vehicle to normal operating temperatures. Drive the vehicle on a smooth road while accelerating through the gears with light throttle application. Pay particular attention during the EMCC shifts that take place between 3rd and 4th gears above 40 mph. If vehicle shudder is noticed during the shifts, perform the Repair Procedure. PARTS REQUIRED: 1 04864505 Filter, 41TE Transaxle 1 04796730 Filter, 42LE Transaxle AR(1) 06032780 0-Ring, Filter AR 04798233 Oil, ATF+2 Type 7176 (Qts) AR(1) 82300234 Sealant, RTV POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-55-01-96 1.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-05-97 > Mar > 97 > A/T - 41TE/42LE Shudder During EMCC Shift > Page 1255 This repair involves changing the transaxle fluid and filter, driving the vehicle 10 miles and changing the transaxle fluid a second time. 1. Raise the vehicle on a hoist. 2. Clean the transaxle oil pan area and adjoining surfaces. 3. Loosen the transaxle oil pan and drain the fluid into a suitable container. 4. Remove the pan and clean all sealant form the pan and transaxle mating surfaces. Clean the inside of the pan and magnet. 5. Separate the filter and 0-ring from the valve body. Inspect the 0-ring for cuts or improper installation which can lead to delayed garage shifts. 6. Install a new filter p/n 04796730 (42LE) or p/n 04864505 (41TE). Replace the 0-ring p/n 06032780 as necessary. 7. Apply a 1/8 inch bead of Mopar RTV Sealant p/n 82300234 to the mounting flange of the transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to the transaxle and torque the bolts to 19 Nm (165 in. Lbs.). 8. Lower the vehicle and add 4 quarts of Mopar ATF +2 Type 7176 transaxle fluid p/n 04798233 through the transaxle fill tube. 9. Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied, press your foot on the service brake and cycle the transaxle from park to all gear positions ending in neutral or park. 10. Check the transaxle fluid level and add an appropriate amount to bring the level to 3 mm (1/8 in.) below the ADD mark on the dipstick. 11. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range. 12. Drive the vehicle a minimum of 10 miles. 13. Repeat steps 1 through 4. 14. Separate the filter from the valve body to allow additional fluid to drain from the transaxle. Inspect the filter 0-ring for any damage and replace if necessary. 15. After the transaxle has stopped draining, re-install the filter and 0-ring. 16. Complete re-assembly and filling of the transaxle by following steps 7 through 11. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature Fluid Filter - A/T: All Technical Service Bulletins A/T - Slips In Reverse At Low Temperature NO: 21-06-96 GROUP: Transmission DATE: Apr. 26, 1996 SUBJECT: Slips In Reverse At Low Temperature MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX). SYMPTOM/CONDITION: Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these temperature/time conditions is considered normal. DIAGNOSIS: If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If the transaxle also slips going into Drive, further diagnosis is required. PARTS REQUIRED: 1 4659837 Piston, Low/Reverse Servo AR 4318025 Sealant, RTV AR 4467721 Fluid, Mopar Automatic Transmission Type 7176 1 4269649 Filter, Transaxle 1 4269671 Gasket, Transaxle Filter REPAIR PROCEDURE: This bulletin involves installing a revised Low/Reverse servo piston. 1. Raise the vehicle with an appropriate hoist. 2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam. 3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside the oil pan and magnet. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1260 4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the transaxle oil filter and gasket from the valve body and discard (refer to Figure 1). 5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to Figure 2). 6. Remove the neutral start/back-up lamp switch (refer to Figure 3). 7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes from the transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1261 8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse servo (refer to Figures 5, 6 and 7). 9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo assembly. 10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs. (4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm). 11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs. (12 Nm). 12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm). 13. Attach the parking rod to the valve body with the parking rod E-clip. 14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the 2 attaching screws to 40 in. lbs. (5 Nm). 15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to 165 in. lbs. (19 Nm). 16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. 17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. 18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the ADD mark on dipstick. 19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1262 Labor Operation No: 21-80-10-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-05-97 > Mar > 97 > A/T - 41TE/42LE Shudder During EMCC Shift Technical Service Bulletin # 21-05-97 Date: 970314 A/T - 41TE/42LE Shudder During EMCC Shift NO: 21-05-97 GROUP: Transmission DATE: Mar. 14, 1997 SUBJECT: 41TE/42LE Transaxle Shudder During an EMCC (Electronically Modulated Converter Clutch) Shift MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: 1989 TO 1995 MODELS SHOULD HAVE TSB 18-24-95 PERFORMED PRIOR TO PROCEEDING WITH THIS REPAIR PROCEDURE. SYMPTOM/CONDITION: Transaxle shudder during a 3rd gear to 3rd gear partial EMCC (Electronically Modulated Converter Clutch) engagement, 3rd gear partial EMCC to 4th gear partial EMCC engagement, or 4th gear to 4th gear EMCC engagement. Vehicle speed will be above 40 mph to obtain these shift points. This condition can be the result of worn out automatic transaxle fluid, using additives in the transaxle fluid, or from using the wrong type fluid (Dexron II, III, or Mercon) in the transaxle. NOTE: MOPAR ATF+2 TYPE 7176 IS THE ONLY RECOMMENDED FLUID FOR THESE TRANSAXLES. DIAGNOSIS: Bring the vehicle to normal operating temperatures. Drive the vehicle on a smooth road while accelerating through the gears with light throttle application. Pay particular attention during the EMCC shifts that take place between 3rd and 4th gears above 40 mph. If vehicle shudder is noticed during the shifts, perform the Repair Procedure. PARTS REQUIRED: 1 04864505 Filter, 41TE Transaxle 1 04796730 Filter, 42LE Transaxle AR(1) 06032780 0-Ring, Filter AR 04798233 Oil, ATF+2 Type 7176 (Qts) AR(1) 82300234 Sealant, RTV POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-55-01-96 1.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-05-97 > Mar > 97 > A/T - 41TE/42LE Shudder During EMCC Shift > Page 1268 This repair involves changing the transaxle fluid and filter, driving the vehicle 10 miles and changing the transaxle fluid a second time. 1. Raise the vehicle on a hoist. 2. Clean the transaxle oil pan area and adjoining surfaces. 3. Loosen the transaxle oil pan and drain the fluid into a suitable container. 4. Remove the pan and clean all sealant form the pan and transaxle mating surfaces. Clean the inside of the pan and magnet. 5. Separate the filter and 0-ring from the valve body. Inspect the 0-ring for cuts or improper installation which can lead to delayed garage shifts. 6. Install a new filter p/n 04796730 (42LE) or p/n 04864505 (41TE). Replace the 0-ring p/n 06032780 as necessary. 7. Apply a 1/8 inch bead of Mopar RTV Sealant p/n 82300234 to the mounting flange of the transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to the transaxle and torque the bolts to 19 Nm (165 in. Lbs.). 8. Lower the vehicle and add 4 quarts of Mopar ATF +2 Type 7176 transaxle fluid p/n 04798233 through the transaxle fill tube. 9. Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied, press your foot on the service brake and cycle the transaxle from park to all gear positions ending in neutral or park. 10. Check the transaxle fluid level and add an appropriate amount to bring the level to 3 mm (1/8 in.) below the ADD mark on the dipstick. 11. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range. 12. Drive the vehicle a minimum of 10 miles. 13. Repeat steps 1 through 4. 14. Separate the filter from the valve body to allow additional fluid to drain from the transaxle. Inspect the filter 0-ring for any damage and replace if necessary. 15. After the transaxle has stopped draining, re-install the filter and 0-ring. 16. Complete re-assembly and filling of the transaxle by following steps 7 through 11. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Drain and Refill Fluid Filter - A/T: Service and Repair Fluid Drain and Refill 1. Raise vehicle on a hoist. 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. 4. Clean the oil pan and magnet. Reinstall pan using new MOPAR RTV sealant. Tighten oil pan bolts to 19 Nm (165 inch lbs.). 5. Pour four quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602 through the fill tube. 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. Add sufficient fluid to bring level to 1/8 inch below the ADD mark. CAUTION: Do not overfill transaxle. Do not acid oil if level is between: Lower holes for warm oil (100°F). Upper holes for hot oil (180°F). 8. Recheck fluid level after transaxle is at normal operating temperature. The level should be in the HOT region. 9. To prevent dirt from entering transaxle, make certain that dipstick is seated into the dipstick fill tube. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Drain and Refill > Page 1271 Fluid Filter - A/T: Service and Repair Fluid & Filter Change When the factory fill fluid is changed, only fluids labeled MOPAR ATF Plus 4 (Automatic Transmission fluid) Type 7176, or equivalent should be used. A filter change should be made at the time of the oil change. Also the magnet (on the inside of the oil pan) should be cleaned with a clean, dry cloth. If the transaxle is disassembled for any reason, the fluid and filter should be changed. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fig 1 Intake Plenum Mounting Bolts Fuel Pressure Release Procedure - Typical WARNING: The fuel system is under constant pressure of approximately 48 psi (330 kPa), even when the engine is OFF. 1. Disconnect negative battery cable. 2. Loosen fuel tank filler cap to relieve fuel tank pressure. 3. Remove cap on fuel rail pressure test port (Fig. 1). 4. Place one end of fuel pressure release hose, tool C-4799-1 (or equivalent), in an approved gasoline container. Connect the other end of this hose to the fuel rail service port. Fuel pressure should bleed off into container. 5. Perform necessary fuel system service procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair Oil Filter: Service and Repair CAUTION: When servicing the oil filter avoid deforming the filter can by installing the remove/install tool band strap against the can-to-base lock seam. The lock seam joining the can to the base is reinforced by the base plate. 1. Using Tool C-4065, or equivalent, turn filter counterclockwise to remove from base. Properly discard filter. 2. Wipe base clean, then inspect gasket contact surface. 3. Lubricate gasket of new filter with clean engine oil. 4. Install new filter until gasket contacts base. Tighter filter 1 turn or 20 Nm (15 ft. Lbs.). Use filter wrench if necessary. 5. Start engine and check for leaks. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Page 1279 Oil Filter Wrench C-4065 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Specifications Refrigerant Filter: Specifications The oil designated for this vehicle is ND8 PAG (polyalkalene glycol). Front A/C - Filter-Drier 15 ml (0.5 oz) Dual A/C - Filter-Drier 30 ml (1.0 oz) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hoses Heater Hose: Service and Repair Heater Hoses Review Safety Precautions and Warnings the in General Information section before proceeding with this operation. 1. Drain engine cooling system. 2. Loosen clamps at each end of heater hose to be removed. CAUTION: When removing hoses from heater core inlet or outlet nipples, do not use excessive force. Heater core may become damaged and leak engine coolant. 3. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the hose will not come off, slice the hose at the connector nipple and peal off heater hose. This method will require heater hose replacement. To install, reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hoses > Page 1289 Heater Hose: Service and Repair Underbody Plumbing WARNING: THE ENGINE COOLING SYSTEM MUST BE RELIEVED OF ALL PRESSURE. 1. Drain the engine cooling system. 2. In the engine compartment, and disconnect two auxiliary rear heater hoses from the (front) heater hose tee fittings. 3. Hoist the vehicle. Disconnect two push-together couplings from the auxiliary rear heater core tubes protruding through the floor pan. 4. Remove four bolts and one pal nut holding the plumbing to the floor pan and lower the plumbing from the vehicle. To Install, Reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > A/C Hose - Squeaking Noise Hose/Line HVAC: Technical Service Bulletins A/C Hose - Squeaking Noise NO: 24-02-94 GROUP: Heat & A/C DATE: Jan. 14, 1994 SUBJECT: Squeak in Right Shock Tower Area MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: If a squeaking noise seems to be coming from the right shock tower, a possible cause is the right shock tower A/C hose support bracket. This should be checked prior to looking elsewhere on or in the shock tower. If the insulation foam between the bracket and hoses is mis-positioned or worn through, a squeak may occur under driving conditions. Inspect the hose and bracket area and relocate or replace the foam or bend the bracket to eliminate any metal-to-metal contact. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 1294 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Removal and Installation Hose/Line HVAC: Service and Repair Removal and Installation REMOVAL (1) Recover A/C system. (2) Remove upper generator bracket. See: Starting and Charging/Charging System. (3) Remove ground wire at cowl. (4) Remove expansion valve plate and bolt (Fig.50. (5) Remove liquid line from expansion valve. (6) Remove wire connector at pressure transducer. (7) Remove liquid line mounting bracket at right frame rail. (8) Using access slot between radiator crossmember arid grille, loosen liquid line mounting plate at filter-drier. Remove liquid line from filter-drier. It may be necessary to bend liquid line in half to remove line. The replacement Tine is a two-piece assembly. INSTALLATION (1) To install, reverse preceding operation. Replace all O-rings. Install two-piece line in place of original part. Assemble line halves after it is installed on vehicle. (2) Evacuate and recharge A/C system. SUCTION LINE REMOVAL (1) Recover A/C system. (2) Remove suction line mounting nut at compressor (Fig. 51). (3) Remove upper generator bracket. See: Starting and Charging/Charging System (4) Remove ground wire at cowl. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Removal and Installation > Page 1297 (5) Remove expansion valve line plate nut (Fig.52). (6) Remove suction line mounting bracket. (7) Remove suction line. INSTALLATION (1) To install, reverse preceding operation. Replace all 0-rings. (2) Evacuate and recharge A/C system. DISCHARGE LINE REMOVAL (1) Recover A/C system (2) Remove discharge line mounting nut at compressor (Fig. 53). (3) Remove discharge line at the top fitting on the condenser (Fig. 54). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Removal and Installation > Page 1298 INSTALLATION (1) To install, reverse preceding operation. Replace all 0-rings. (2) Evacuate and recharge A/C system. (3) Perform HVAC Control calibration and test procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Removal and Installation > Page 1299 Hose/Line HVAC: Service and Repair Rear Air Conditioning Lines REMOVAL WARNING: THE REFRIGERANT SYSTEM MUST BE EMPTY BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Hoist the vehicle. Disconnect two tube-fittings from the engine compartment plumbing. 2. Remove the bolt from the unified plumbing block (left side of car, outboard of rail, forward of fuel tank). 3. Carefully pull refrigerant line assembly down (take care NOT to scratch the sealing surface with the tube pilots). Remove and discard the aluminum gasket and cover unit sealing surface to prevent contamination. 4. Remove two screws holding plumbing to the fuel tank support and left-side support rail (near muffler support bracket). 5. Remove two screws holding the plumbing to the floor pan. 6. Disconnect the parking brake system at hook above muffler and the cable connection near the support rails. 7. Fish the nylon tubing and unified plumbing block above the muffler support member. 8. Lower the plumbing from the vehicle. 9. Measure the residual oil in the under body plumbing out of each end of the plumbing. The lowside (larger diameter line) has a check valve that can restrict oil flow from the tube-fitting to the unified plumbing end of the hose. Measure clean R134a PAG refrigerant oil to be returned to the refrigerant system. INSTALL 1. Protect the plumbing ends from scratches. If plumbing is new, do not remove the shipping caps until joining together. 2. Reverse the preceding steps from the REMOVAL procedure. 3. New gaskets and O-rings are required for installation. The O-rings must be covered with clean refrigerant oil prior to installation. 4. Connect the tube-fittings to the engine compartment under body plumbing. Avoid misalignment of the threads (cross threading) and tighten to 200 in-lbs 5. Remove the shipping cap from the plumbing side sealing surface and verify that the aluminum gasket is present. 6. Carefully align the pilot tubes of the plumbing line block into the unit (take care not to scratch the sealing surface). 7. Install the bolt through the plumbing plate into the unit sealing plate. Tighten bolt to 200 +/- 30 in lbs (23 +/- 3 Nm). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Use new brake fluid only, to top off the master cylinder or refill system. Never use reclaimed fluid, unmarked or unspecified fluid, fluid not meeting SAE/DOT standards, fluid marked 70R1, or fluid from a container that has been left open. Brake Fluid Type DOT 3 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1304 Brake Fluid: Testing and Inspection Indications of fluid contamination: Swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination: Put small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil contamination. If contaminated: Drain and thoroughly flush system, and replace all rubber parts. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1305 Brake Fluid: Service and Repair Aluminum Master Cylinder NOTES: - Check master cylinder fluid level twice annually. - Master cylinder reservoirs are marked with the words "fill to bottom of rings". - Add DOT 3 fluid to bring the level to the bottom of the primary split ring. CAUTION: Use of brake fluid with a lower boiling point than DOT 3 fluid could result in brake failure during long, hard braking. CAUTION: Do not use fluid which has been stored in an unsealed container. Brake fluid stored in this manner will absorb moisture which could result in brake failure during long, hard braking. CAUTION: Use of petroleum based fluids will result in seal damage. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations Coolant: Technical Service Bulletins Engine - Coolant Recommendations NO: 07-03-97 GROUP: Cooling DATE: May 9, 1997 SUBJECT: Engine Coolant Usage THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-05-93 DATED NOV. 26, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1993 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-94000). THE COMPLETE BULLETIN IS REVISED. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1997 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger/ Power Ram/Power Ram Cab & Chassis 1989 - 1993 (AG) Daytona 1989 (AH) Lancer/LeBaron GTS 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1997 (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1997 (BR) Ram Truck 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1989 - 1992 (MJ) Comanche 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1997 (PR) Prowler 1992 - 1997 (SR) Viper/Viper Coupe 1997 (TJ) Wrangler 1989 - 1997 (XJ) Cherokee 1989 - 1995 (YJ) Wrangler 1993 - 1997 (ZJ) Grand Cherokee DISCUSSION: Some owners have expressed interest in using engine coolants made with propylene glycol instead of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals. Based on recent test data, most owners should not experience significant effects on cooling system performance when using propylene glycol based coolant. The use of national brand propylene glycol based engine coolant that meets the same Chrysler ethylene glycol specification of MS-7170 (or equivalent ASTM D5216) is acceptable for Chrysler built vehicles. NOTE: ANTIFREEZE SOLD FOR PROTECTING PLUMBING ETC. (RV ANTIFREEZE) IS NOT A SUITABLE ENGINE COOLANT. However, owners should be discouraged from changing their engine coolant prior to the regularly scheduled maintenance period. Prematurely changing engine coolant unnecessarily adds to the risk of environmental exposure. Sufficient freeze protection for the region should be maintained. However, do not use more than a 55% solution (-35 F, -37 C). Use the chart that accompanies the propylene glycol coolant, since a higher concentration is required to obtain the same freeze points as ethylene glycol coolant. If the temperatures for your region fall below this, use ethylene glycol coolant. Under severe driving conditions (towing a trailer in hot weather etc.) there may be a slight loss in cooling performance. If this is noticed, the system should be changed back to ethylene glycol coolant. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations > Page 1310 The two types of coolant should not be mixed. The standard testers for measuring freeze protection will not provide an accurate reading when this occurs. If the cooling system is changed to propylene glycol, all the ethylene glycol coolant should be removed using an approved cooling system flush procedure. The freeze protection of propylene glycol cannot be measured with a standard cooling system hydrometer. A refractometer or hydrometer calibrated for propylene glycol is the preferred test tool. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Page 1311 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature Fluid - A/T: Customer Interest A/T - Slips In Reverse At Low Temperature NO: 21-06-96 GROUP: Transmission DATE: Apr. 26, 1996 SUBJECT: Slips In Reverse At Low Temperature MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX). SYMPTOM/CONDITION: Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these temperature/time conditions is considered normal. DIAGNOSIS: If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If the transaxle also slips going into Drive, further diagnosis is required. PARTS REQUIRED: 1 4659837 Piston, Low/Reverse Servo AR 4318025 Sealant, RTV AR 4467721 Fluid, Mopar Automatic Transmission Type 7176 1 4269649 Filter, Transaxle 1 4269671 Gasket, Transaxle Filter REPAIR PROCEDURE: This bulletin involves installing a revised Low/Reverse servo piston. 1. Raise the vehicle with an appropriate hoist. 2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam. 3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside the oil pan and magnet. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1320 4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the transaxle oil filter and gasket from the valve body and discard (refer to Figure 1). 5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to Figure 2). 6. Remove the neutral start/back-up lamp switch (refer to Figure 3). 7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes from the transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1321 8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse servo (refer to Figures 5, 6 and 7). 9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo assembly. 10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs. (4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm). 11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs. (12 Nm). 12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm). 13. Attach the parking rod to the valve body with the parking rod E-clip. 14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the 2 attaching screws to 40 in. lbs. (5 Nm). 15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to 165 in. lbs. (19 Nm). 16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. 17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. 18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the ADD mark on dipstick. 19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1322 Labor Operation No: 21-80-10-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts Fluid - A/T: Customer Interest A/T - Harsh Gear Engagement/Upshifts/Downshifts NO.: 21-36-93 GROUP: Transmission DATE: Dec. 10, 1993 SUBJECT: Improved Transmission Shift Schedule MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH 09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION. SYMPTOM/CONDITION: Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1 kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary Neutral/Drive garage shifts. Park to Reverse noise (grunt). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4686478 Transmission Control Module AR 4467721 Transmission Fluid - ATF Plus (7176) REPAIR PROCEDURE: This repair involves the replacement of the transmission control module with a module that incorporates revised software, changing the transmission fluid, setting the pinion factor, and transaxle quick learn. 1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is currently installed on the vehicle. This is accomplished by choosing the TSB option under Adjustments. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS INSPECTED AT THE RETURN CENTER. 2. Replace the transmission control module with the new module, following the procedures outlined in the appropriate service manual. 3. Change the transmission fluid following the procedure outlined in the service manual. NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER. 4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and then place gear selector in Neutral. 5. Using the procedures listed in the service manual complete the following: a. Quick Learn Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 1327 b. Electronic Pinion Factor Procedure 6. Drive the vehicle at least 10 miles. 7. Change the transmission fluid again following the procedure outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-06-90 2.1 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 21-05-97 > Mar > 97 > A/T - 41TE/42LE Shudder During EMCC Shift Technical Service Bulletin # 21-05-97 Date: 970314 A/T - 41TE/42LE Shudder During EMCC Shift NO: 21-05-97 GROUP: Transmission DATE: Mar. 14, 1997 SUBJECT: 41TE/42LE Transaxle Shudder During an EMCC (Electronically Modulated Converter Clutch) Shift MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: 1989 TO 1995 MODELS SHOULD HAVE TSB 18-24-95 PERFORMED PRIOR TO PROCEEDING WITH THIS REPAIR PROCEDURE. SYMPTOM/CONDITION: Transaxle shudder during a 3rd gear to 3rd gear partial EMCC (Electronically Modulated Converter Clutch) engagement, 3rd gear partial EMCC to 4th gear partial EMCC engagement, or 4th gear to 4th gear EMCC engagement. Vehicle speed will be above 40 mph to obtain these shift points. This condition can be the result of worn out automatic transaxle fluid, using additives in the transaxle fluid, or from using the wrong type fluid (Dexron II, III, or Mercon) in the transaxle. NOTE: MOPAR ATF+2 TYPE 7176 IS THE ONLY RECOMMENDED FLUID FOR THESE TRANSAXLES. DIAGNOSIS: Bring the vehicle to normal operating temperatures. Drive the vehicle on a smooth road while accelerating through the gears with light throttle application. Pay particular attention during the EMCC shifts that take place between 3rd and 4th gears above 40 mph. If vehicle shudder is noticed during the shifts, perform the Repair Procedure. PARTS REQUIRED: 1 04864505 Filter, 41TE Transaxle 1 04796730 Filter, 42LE Transaxle AR(1) 06032780 0-Ring, Filter AR 04798233 Oil, ATF+2 Type 7176 (Qts) AR(1) 82300234 Sealant, RTV POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-55-01-96 1.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 21-05-97 > Mar > 97 > A/T - 41TE/42LE Shudder During EMCC Shift > Page 1333 This repair involves changing the transaxle fluid and filter, driving the vehicle 10 miles and changing the transaxle fluid a second time. 1. Raise the vehicle on a hoist. 2. Clean the transaxle oil pan area and adjoining surfaces. 3. Loosen the transaxle oil pan and drain the fluid into a suitable container. 4. Remove the pan and clean all sealant form the pan and transaxle mating surfaces. Clean the inside of the pan and magnet. 5. Separate the filter and 0-ring from the valve body. Inspect the 0-ring for cuts or improper installation which can lead to delayed garage shifts. 6. Install a new filter p/n 04796730 (42LE) or p/n 04864505 (41TE). Replace the 0-ring p/n 06032780 as necessary. 7. Apply a 1/8 inch bead of Mopar RTV Sealant p/n 82300234 to the mounting flange of the transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to the transaxle and torque the bolts to 19 Nm (165 in. Lbs.). 8. Lower the vehicle and add 4 quarts of Mopar ATF +2 Type 7176 transaxle fluid p/n 04798233 through the transaxle fill tube. 9. Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied, press your foot on the service brake and cycle the transaxle from park to all gear positions ending in neutral or park. 10. Check the transaxle fluid level and add an appropriate amount to bring the level to 3 mm (1/8 in.) below the ADD mark on the dipstick. 11. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range. 12. Drive the vehicle a minimum of 10 miles. 13. Repeat steps 1 through 4. 14. Separate the filter from the valve body to allow additional fluid to drain from the transaxle. Inspect the filter 0-ring for any damage and replace if necessary. 15. After the transaxle has stopped draining, re-install the filter and 0-ring. 16. Complete re-assembly and filling of the transaxle by following steps 7 through 11. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature Fluid - A/T: All Technical Service Bulletins A/T - Slips In Reverse At Low Temperature NO: 21-06-96 GROUP: Transmission DATE: Apr. 26, 1996 SUBJECT: Slips In Reverse At Low Temperature MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX). SYMPTOM/CONDITION: Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these temperature/time conditions is considered normal. DIAGNOSIS: If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If the transaxle also slips going into Drive, further diagnosis is required. PARTS REQUIRED: 1 4659837 Piston, Low/Reverse Servo AR 4318025 Sealant, RTV AR 4467721 Fluid, Mopar Automatic Transmission Type 7176 1 4269649 Filter, Transaxle 1 4269671 Gasket, Transaxle Filter REPAIR PROCEDURE: This bulletin involves installing a revised Low/Reverse servo piston. 1. Raise the vehicle with an appropriate hoist. 2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam. 3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside the oil pan and magnet. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1338 4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the transaxle oil filter and gasket from the valve body and discard (refer to Figure 1). 5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to Figure 2). 6. Remove the neutral start/back-up lamp switch (refer to Figure 3). 7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes from the transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1339 8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse servo (refer to Figures 5, 6 and 7). 9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo assembly. 10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs. (4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm). 11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs. (12 Nm). 12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm). 13. Attach the parking rod to the valve body with the parking rod E-clip. 14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the 2 attaching screws to 40 in. lbs. (5 Nm). 15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to 165 in. lbs. (19 Nm). 16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. 17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. 18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the ADD mark on dipstick. 19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 1340 Labor Operation No: 21-80-10-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts Fluid - A/T: All Technical Service Bulletins A/T - Harsh Gear Engagement/Upshifts/Downshifts NO.: 21-36-93 GROUP: Transmission DATE: Dec. 10, 1993 SUBJECT: Improved Transmission Shift Schedule MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH 09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION. SYMPTOM/CONDITION: Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1 kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary Neutral/Drive garage shifts. Park to Reverse noise (grunt). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4686478 Transmission Control Module AR 4467721 Transmission Fluid - ATF Plus (7176) REPAIR PROCEDURE: This repair involves the replacement of the transmission control module with a module that incorporates revised software, changing the transmission fluid, setting the pinion factor, and transaxle quick learn. 1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is currently installed on the vehicle. This is accomplished by choosing the TSB option under Adjustments. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS INSPECTED AT THE RETURN CENTER. 2. Replace the transmission control module with the new module, following the procedures outlined in the appropriate service manual. 3. Change the transmission fluid following the procedure outlined in the service manual. NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER. 4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and then place gear selector in Neutral. 5. Using the procedures listed in the service manual complete the following: a. Quick Learn Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 1345 b. Electronic Pinion Factor Procedure 6. Drive the vehicle at least 10 miles. 7. Change the transmission fluid again following the procedure outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-06-90 2.1 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 21-05-97 > Mar > 97 > A/T - 41TE/42LE Shudder During EMCC Shift Technical Service Bulletin # 21-05-97 Date: 970314 A/T - 41TE/42LE Shudder During EMCC Shift NO: 21-05-97 GROUP: Transmission DATE: Mar. 14, 1997 SUBJECT: 41TE/42LE Transaxle Shudder During an EMCC (Electronically Modulated Converter Clutch) Shift MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: 1989 TO 1995 MODELS SHOULD HAVE TSB 18-24-95 PERFORMED PRIOR TO PROCEEDING WITH THIS REPAIR PROCEDURE. SYMPTOM/CONDITION: Transaxle shudder during a 3rd gear to 3rd gear partial EMCC (Electronically Modulated Converter Clutch) engagement, 3rd gear partial EMCC to 4th gear partial EMCC engagement, or 4th gear to 4th gear EMCC engagement. Vehicle speed will be above 40 mph to obtain these shift points. This condition can be the result of worn out automatic transaxle fluid, using additives in the transaxle fluid, or from using the wrong type fluid (Dexron II, III, or Mercon) in the transaxle. NOTE: MOPAR ATF+2 TYPE 7176 IS THE ONLY RECOMMENDED FLUID FOR THESE TRANSAXLES. DIAGNOSIS: Bring the vehicle to normal operating temperatures. Drive the vehicle on a smooth road while accelerating through the gears with light throttle application. Pay particular attention during the EMCC shifts that take place between 3rd and 4th gears above 40 mph. If vehicle shudder is noticed during the shifts, perform the Repair Procedure. PARTS REQUIRED: 1 04864505 Filter, 41TE Transaxle 1 04796730 Filter, 42LE Transaxle AR(1) 06032780 0-Ring, Filter AR 04798233 Oil, ATF+2 Type 7176 (Qts) AR(1) 82300234 Sealant, RTV POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-55-01-96 1.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 21-05-97 > Mar > 97 > A/T - 41TE/42LE Shudder During EMCC Shift > Page 1351 This repair involves changing the transaxle fluid and filter, driving the vehicle 10 miles and changing the transaxle fluid a second time. 1. Raise the vehicle on a hoist. 2. Clean the transaxle oil pan area and adjoining surfaces. 3. Loosen the transaxle oil pan and drain the fluid into a suitable container. 4. Remove the pan and clean all sealant form the pan and transaxle mating surfaces. Clean the inside of the pan and magnet. 5. Separate the filter and 0-ring from the valve body. Inspect the 0-ring for cuts or improper installation which can lead to delayed garage shifts. 6. Install a new filter p/n 04796730 (42LE) or p/n 04864505 (41TE). Replace the 0-ring p/n 06032780 as necessary. 7. Apply a 1/8 inch bead of Mopar RTV Sealant p/n 82300234 to the mounting flange of the transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to the transaxle and torque the bolts to 19 Nm (165 in. Lbs.). 8. Lower the vehicle and add 4 quarts of Mopar ATF +2 Type 7176 transaxle fluid p/n 04798233 through the transaxle fill tube. 9. Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied, press your foot on the service brake and cycle the transaxle from park to all gear positions ending in neutral or park. 10. Check the transaxle fluid level and add an appropriate amount to bring the level to 3 mm (1/8 in.) below the ADD mark on the dipstick. 11. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range. 12. Drive the vehicle a minimum of 10 miles. 13. Repeat steps 1 through 4. 14. Separate the filter from the valve body to allow additional fluid to drain from the transaxle. Inspect the filter 0-ring for any damage and replace if necessary. 15. After the transaxle has stopped draining, re-install the filter and 0-ring. 16. Complete re-assembly and filling of the transaxle by following steps 7 through 11. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transaxle/Transmission - Automatic See TSB 21-010-06 4/14/2006 CAPACITY, Initial Refill*: All with transverse engine............................................................................ ......................................................................................3.8 Liters 4.0 Quarts All with longitudinal engine................................................................................................................... ............................................4.2 Liters 4.5 Quarts *With the engine at operating temperature, shift transmission through all gears. Check fluid level in PARK and add fluid as needed 1993 Grand Caravan adding or replace, Mopar ATF Plus 4 type 9602. Initial Refill Capacity Automatic.............................................................................................................................................. ..........................................................................AP‡ CAPACITY, Initial Refill*: All with transverse en gine....................................................................................................................................................... ...........3.8 Liters 4.0 Quarts All with longitudinal engine................................................................................................................... ............................................4.2 Liters 4.5 Quarts *With the engine at operating temperature, shift transmission through all gears. Check fluid level in PARK and add fluid as needed ‡May use AF or MA only when AP is not available only for "Topping off" Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1354 Fluid - A/T: Fluid Type Specifications See TSB 21-010-06 4/14/2006 ATF Plus 4 Type 9602 Oil Type ................................................................................................................................................. Mopar (R) ATF Plus 4 Type 9602, Or Equivalent. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check Fluid - A/T: Service and Repair Fluid Level & Condition Check Fluid Level The transmission and differential sump have a common oil sump with a opening between the two. The torque converter fills in both the "P" Park and "N" Neutral positions. Place the selector lever in "P" Park to check fluid level. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. This will assure complete oil level stabilization between differential and transmission. The fluid should be at normal operating temperature (approximately 82 C. or 180 F). The fluid level is correct if it is in the "HOT" region (cross-hatched area) on the oil level indicator. Fluid Condition Along with fluid level, it is important to check the condition of the fluid. - When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transaxle overhaul is needed. Be sure to examine the fluid on the dipstick closely. - If there is any doubt about its condition, drain out a sample for a double check. Note: After the fluid has been checked, seat the dipstick fully to seal out water and dirt. Low Fluid Level Symptoms Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. in any hydraulic system, air bubbles will make the fluid spongy, therefore pressures will be low and build up slowly. Improper Filling Level Symptoms Improper filling can also raise the fluid level too high. - When the transaxle has too much fluid, the gears churn up foam and cause the same conditions which occur with a low fluid level. In either case the air bubbles can cause over heating, fluid oxidation, and varnishing, which can interfere with normal valve, clutch and accumulator operation. Foaming can also result in fluid escaping from the transaxle vent, where it may be mistaken for a leak. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check > Page 1357 Fluid - A/T: Service and Repair Fluid and Filter Change Fluid and Filter Change When the factory fill fluid is changed, only fluids labeled Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 should be used. A filter change should be made at the time of oil change. Also the magnet (on the inside of the oil pan) should be cleaned with a clean dry cloth. If the transaxle is disassembled for any reason, the fluid and filter should be changed. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check > Page 1358 Fluid - A/T: Service and Repair Fluid Drain and Refill Procedure 1. Raise vehicle on a hoist. 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. 4. Clean the oil pan and magnet. Reinstall pan using Mopar RTV Sealant. Tighten oil pan bolts to 19 Nm (165 in-lbs). 5. Pour four quarts of Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 through the fill tube. 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. Add sufficient fluid to bring level to 1/8 inch below the ADD mark on the dipstick. CAUTION: Do not over fill transaxle. Do not add oil if level is between: Lower holes for warm oil (100F). Upper holes for hot oil (180F). 8. Recheck fluid level after transaxle is at normal operating temperature. The level should be in the HOT region. 9. To prevent dirt from entering transaxle, make certain that dipstick is seated into the dipstick fill tube. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications Fluid - Differential: Specifications TYPE ................................................................................................................................................... ........................................................... 80W-90 GL-5 CAPACITY, Refill: All with longitudinal engine .......................................................................................................................................................... 0.9 Liters 2.0 Pints Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications Engine Oil: Specifications TYPE.................................................................................................................................................... ...............................................................SG, SG/CD* *Preferred with Turbo engine SG/CD required for 1993 Turbo engine. CAPACITY, Refill: 3.3L Concorde, Intrepid, Vision ...................................................................................................................................................... 4.3 Liters 4.5 Quarts 3.5L, all ................................................................................................................................................ ........................................... 4.8 Liters 5.0 Quarts All others .............................................................................................................................................. ........................................... 3.8 Liters 4.0 Quarts Capacity shown is without filter. When replacing filter, additional oil may be needed All engine. above 0°F (-18°C)............................................................................................................... .....................................................................10W-30* 2.5L Van, 3.5L & Turbo below 32°F (0°C)........ .........................................................................................................................................................5 W-30‡ Non-Turbo ex. 2.5L Van below 100°F (38°C)....................................................................................... ........................................................................5W-30 *Preferred in all Turbo, 2.5L & 3.5L ‡Preferred in all non-Turbo ex. 2.5L Van Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service Precautions > Technician Safety Information Engine Oil: Technician Safety Information 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 GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service Precautions > Technician Safety Information > Page 1367 Engine Oil: Vehicle Damage Warnings CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service Precautions > Page 1368 Engine Oil: Description and Operation CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result. API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certified or an oil that conforms to the API Service Grade SH or SH/CD. SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. SAE 30 specifies a single viscosity engine oil. Engine oils also have multiple viscosities. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation. ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. They are designated as either ENERGY CONSERVING or ENERGY CONSERVING II. CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans. ENGINE OIL ADDITIVES In some instances, such as infrequent operation, short trip driving, and during break-in after a major overhaul, addition of special materials containing anti-rust and anti-scuff additives are beneficial. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service Precautions > Page 1369 Engine Oil: Testing and Inspection CHECKING OIL LEVEL To assure proper engine lubrication, the engine oil must be maintained at the correct level. Check the oil level at regular intervals, such as every fuel stop. The best time to check the oil level is about 5 minutes after a fully warmed-up engine is shut off, or before starting the vehicle after it has sat overnight. Checking the oil while the vehicle is on level ground, will improve the accuracy of the oil level readings. Maintain the oil level between the MIN and MAX markings on the dipstick. Adding one quart of oil when the reading is at the MIN mark will result in a MAX reading on these engines. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service Precautions > Page 1370 Engine Oil: Service and Repair CHANGING ENGINE OIL Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. Refer. to Hoisting and Jacking Recommendations. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 6. Install drain plug in crankcase. 7. Lower vehicle and fill crankcase with specified type and amount of engine oil. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > R 134A Refrigerant - Leak Detection Systems Refrigerant: Technical Service Bulletins R 134A Refrigerant - Leak Detection Systems NO.: 24-20-93 GROUP: Air Conditioning DATE: Jul. 30, 1993 SUBJECT: R-134A Refrigerant Leak Detection MODELS: DISCUSSION: Numerous R-134A leak detection units are on the market. Some units are better than others, and keep in mind R-134A is more difficult to detect than R-12 because of R-134A's smaller molecular structure. Listed below are the R-134A leak detection units currently approved by Chrysler: HITECH Instruments models HI 300 TEL, HI 350, HI 400 NOVA TEL, and HI 450 NOVA. Leybold Inficon models HLD4000 and D/TEC. OTC/Yokogawa model H10N. All Jeep/Eagle dealers were shipped R-134A equipment in March 1992 to be able to service the ZJ products and Chrysler/Plymouth/Dodge dealers were shipped the same equipment in May 1993. A HITECH Instruments, Model HI 300 TEL leak detector, was included in these equipment packages. Use of any other R-134A leak detection equipment will lead to improper diagnosis, repeat repairs and customer dissatisfaction. HITECH Instruments Models are available through Professional Service Equipment. Points to keep in mind when performing R-134A leak detection: * Testing should be performed 5-7 minutes after A/C system has be turned off. * The hood should be raised at least 5 minutes prior to performing leak detection. This is to help ensure any accumulation of R-134A can dissipate and prevent detecting false leaks throughout the engine compartment. * The probe should be moved at a rate of 1-2 inches per second and no more than 1/2 inch from the surface being checked. DO NOT HOLD THE PROBE IN ONE LOCATION OR ALLOW THE PROBE TO TOUCH ANY SURFACE OR LIQUID. Doing so may contaminate the probe and cause false readings. * Probe along the bottom side of the components because R-134A is heavier than air. * Leak detector probes are very sensitive to contaminants. Do not expose probes to lubricants, paint, welding and mastic fumes, vehicle fuel, exhaust or coolant, halogenated solvents, chlorinated water or steam, dust, powder, or direct streams of R-12 or R-134A. Contaminants cause false readings. * Always follow the leak detector manufacturer's instructions very closely. * A properly maintained and calibrated APPROVED LEAK DETECTOR is your best tool for accurate leak detection and customer satisfaction. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > R 134A Refrigerant - Leak Detection Systems > Page 1375 Refrigerant: Technical Service Bulletins R 134A Refrigerant - Leak Detection NO.: 24-13-94 GROUP: Air Conditioning DATE: Sep. 9, 1994 SUBJECT: R-134a Refrigerant Leak Detection MODELS: 1994 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1994 - 1995 (AB) Ram Van/Ram Wagon 1994 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1994 - 1995 (AN) Dakota/Dakota Cab & Chassis 1994 (AP) Shadow/Sundance 1993 - 1995 (AS) Caravan/Voyager/Town & Country 1994 (BD) Laser/Talon (Midyear Change) 1994 - 1995 (BR) Ram Truck 1994 - 1995 (B7) Stealth 1994 - 1995 (B8) Colt Vista/Summit Wagon 1994 - 1995 (B9) Colt/Summit 1994 - 1995 (ES) Chrysler Voyager (Export Only) 1995 (FJ) Avenger/Sebring/Talon 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1995 (PL) Neon 1993 - 1995 (SR) Viper 1994 - 1995 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: R-134a refrigerant leaks are more difficult to detect than R-12 because of the smaller molecular structure. Listed below are the R-134a leak detection units currently approved by Chrysler and SAE: HITECH Instruments Models HI 300 TEL, H1350, HI 400 NOVA TEL, and Hi 450 NOVA Leybold Inficon Models HLD4000 and D/TEC OTC/Yokogawa Model H10N NOTE: LEAK DETECTOR PROBES ARE VERY SENSITIVE TO CONTAMINANTS. DO NOT EXPOSE PROBES TO LUBRICANTS, PAINT, WELDING AND MASTIC FUMES, VEHICLE FUEL, EXHAUST OR COOLANT, HALOGENATED SOLVENTS, CHLORINATED WATER OR STEAM, DUST, POWDER, OR DIRECT STREAMS OF R-12 OR R134a. ANY TIME CONTAMINATION IS VISUALLY PRESENT ON THE PROBE, OR THE PROBE IS SUSPECTED OF BEING NEAR A CONTAMINANT, FOLLOW THE MANUFACTURERS RECOMMENDATION FOR CLEANING OR REPLACING THE FILTER/SENSOR. ONLY A PROPERLY MAINTAINED LEAK DETECTOR WILL PROVIDE ACCURATE LEAK DETECTION. TECHNICIAN PROCEDURE FOR USING ELECTRONIC REFRIGERANT LEAK DETECTORS FOR SERVICE OF MOBILE AIR CONDITIONING SYSTEMS SAE Recommended Practice J1628 1. The electronic leak detector shall be operated in accordance with the equipment manufacturer's operating instructions. 2. Leak test with the engine not in operation. 3. The air conditioning system shall be charged with sufficient refrigerant to have a gauge pressure of at least 340 kPa (50 psi) when not in operation. At temperatures below 15~C (59~F), leaks may not be measurable since this pressure may not be reached. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > R 134A Refrigerant - Leak Detection Systems > Page 1376 4. Take care not to contaminate the detector probe if the part being tested is contaminated. If the part is particularly dirty, it should be wiped off with a dry shop towel or blown off with shop air. No cleaners or solvents shall be used, since many electronic detectors are sensitive to their ingredients. 5. Visually trace the entire refrigerant system and look for signs of air conditioning lubricant leakage, damage, or corrosion on all lines, hoses, and components. Each questionable area should be carefully checked with the detector probe, as well as all fittings, hose to line couplings, refrigerant controls, service ports with caps off, brazed or welded areas, and areas around attachment points and holddowns on lines and components. 6. Always follow the refrigerant system around in a continuous path so that no areas of potential leaks are missed. If a leak is found, always continue to test the remainder of the system. 7. At each area checked, the probe should be moved around at a rate of no more than 25 to 50 mm/s (1 to 2 inches/second), and no more than 5 mm (1/4 in.) from the surface completely around the position. Slower and closer movement of the probe greatly improves the likelihood of finding a leak. 8. An apparent leak should be verified at least once by blowing shop air into the area of the suspected leak, if necessary, and repeating the check of the area. In cases of very large leaks, blowing out the area with shop air often helps locate the exact position of a leak. 9. Leak testing of the evaporator core while in the air conditioning module should be accomplished by turning the air conditioning blower on high for a period of 15 seconds minimum, shutting it off, then waiting for the refrigerant to accumulate in the case for time specified by 9.1, then inserting the leak detector probe into the condensate drain hole if no water is present, or into the closest opening in the heating/ventilation/air conditioning case to the evaporator, such as heat duct or vent duct. If the detector alarms, a leak apparently has been found. NOTE: R134a REFRIGERANT IS HEAVIER THAN AIR AND WILL TEND TO STAY LOW IN THE A/C MODULE. 9.1 The accumulation time shall be specified by the leak detector manufacturer in the instructions included with the detector, or a minimum of 2 minutes. 10. Following any service to the refrigerant system of the vehicle, and any other service which disturbs the refrigerant system, a leak test of the repair and of the service ports of the refrigerant system should be done. NOTE: CURRENTLY THERE IS NO CHRYSLER APPROVED R-134A REFRIGERANT LEAK DETECTION DYE AVAILABLE. USE OF AN UNAPPROVED DYE WILL CAUSE DAMAGE TO THE A/C SYSTEM. AN APPROVED DYE WILL BE AVAILABLE IN THE NEAR FUTURE. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications A/C System With Rear AC ....................................................................................................................................... ....................................................... 1.420 kg (50 oz) Without Rear AC .................................................................................................................................. ...................................................... 1.020 kg (36 oz) Capacities Capacities Capacity 2.25 lb (US) Capacities Capacities Capacity 3.25 lb (US) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1379 Refrigerant: Fluid Type Specifications A/C Refrigerant Specifications A/C Refrigerant Specifications Refrigerant type R134a Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications A/C System When all air conditioning system is first assembled, all components (except the compressor) are refrigerant oil free. After the system has been charged with R134a refrigerant and operated, the oil in the compressor is dispersed through the lines and components. The evaporator, condenser, and filter-drier will retain a significant amount of oil, see below. When a component is replaced, the specified amount of refrigerant oil must be added. When the compressor is replaced, the amount of oil that is retained in the rest of the system must be drained from the replacement compressor. When a line or component has ruptured and oil has escaped, the compressor should be removed and drained. The filter-drier must be replaced along with the ruptured part. The oil capacity of the system, minus the amount of oil still in the remaining components, can be measured and poured into the suction port of the compressor. EXAMPLE: On a dual system the evaporator retains 60 ml (2 oz). The condenser retains 30 ml (1 oz) of oil, and system capacity may be 220 ml (7.40 oz) of oil. 220 ml minus 90 ml = 130 ml (4.40 oz). CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were designed to work with R-134a refrigerant. The oil designated for this vehicle is ND-8 PAG (polyalkalene glycol). Front A/C - Compressor ....................................................................................................................................... ................................................. 142 ml (4.73 oz) - Filter-Drier ......................................................................................................................................... ................................................... 15 ml (0.5 oz) - Condenser ......................................................................................................................................... ..................................................... 15 ml (0.5 oz) - Evaporator ......................................................................................................................................... .................................................... 30 ml (1.0 oz) Dual A/C - Compressor ....................................................................................................................................... ................................................... 220 ml (7.4 oz) - Filter-Drier ......................................................................................................................................... ................................................... 30 ml (1.0 oz) - Condenser ......................................................................................................................................... ..................................................... 30 ml (1.0 oz) - Evaporator ......................................................................................................................................... .................................................... 60 ml (2.0 oz) - Rear Evaporator ................................................................................................................................ ..................................................... 60 ml (2.0 oz) Capacities Capacities Ounces Viscosity 4.73 oz (US) ND8 PAG Polyalkaline Glycol Capacities Capacities Ounces Viscosity 7.40 oz (US) ND8 PAG Polyalkaline Glycol Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1384 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, Polyalkylene Glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to an R-134a refrigerant system. Refrigerant oil will absorb any moisture it comes in contact with, including moisture in the air. The oil container should be kept tightly capped until it is ready to be used. Then, cap the oil immediately after using, to prevent contamination. There are different PAG oils available, and each contains a different additive package. The refrigerant oil designated for this vehicle is ND-8 PAG . Use only refrigerant oil of this same type to service the refrigerant system. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Oil Charge Additions Refrigerant Oil: Service and Repair Oil Charge Additions It will not be necessary to check the oil level in the compressor or add oil unless there has been an oil loss. Oil loss at the leak point will be evident by the presence of a wet, shiny surface around the leak. If a leak is detected and the compressor must be removed, it is not necessary to discharge the system unless the refrigerant lines will be removed for service. If the lines will be removed, discharge system as outlined in "System Diagnosis/Evacuating the A/C System" and note the following procedure: 1. Disconnect battery ground cable. 2. Loosen and remove drive belts and disconnect compressor clutch wire lead. 3. Remove refrigerant lines from compressor. 4. Remove compressor attaching nuts and bolts. 5. From suction port on top of compressor, drain refrigerant oil from compressor. 6. Install replacement components. 7. Add system capacity minus the capacity of components that have not been replaced. 8. Reverse procedure to install. 9. Evacuate and recharge system. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Oil Charge Additions > Page 1387 Refrigerant Oil: Service and Repair Purging Compressor The compressor must be purged of air whenever it has been isolated from the system for service. 1. Install oil plugs or reconnect refrigerant lines and manual valves to compressor as needed. 2. Cap service access ports on both manual valves, then rotate low (suction) side service valve counterclockwise to the back-seated position. 3. Rotate high (discharge) side manual valve to mid-position, then slightly loosen cap on high side gauge port to allow refrigerant to force air out of compressor. 4. Back seat high side manual valve, then tighten gauge port cap. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Brakes Bendix ABS System Bleeding Procedure Revision Brake Bleeding: Technical Service Bulletins Brakes - Bendix ABS System Bleeding Procedure Revision NUMBER: 05-01-94 GROUP: Brakes DATE: May 27, 1994 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1994 Town & Country, Caravan and Voyager Service Manual - Publication No. 81-370-4105 DESCRIPTION OF CHANGES Bendix Antilock 4 Bleed Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Brakes Bendix ABS System Bleeding Procedure Revision > Page 1392 5-76 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Brakes Bendix ABS System Bleeding Procedure Revision > Page 1393 5-77 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Brakes Bendix ABS System Bleeding Procedure Revision > Page 1394 5-78 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding Brake Bleeding: Service and Repair About Brake System Bleeding WHEN BLEEDING BRAKES REMEMBER... - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always flush and bleed the brake hydraulic sys. when servicing the brakes, because: Brake fluid absorbs moisture from the air, after 3-4 years of service the water content of the brake fluid may be as high as 6-7%. This significantly reduces the boiling point of the brake fluid which may result in a soft pedal or brake failure during prolonged or severe braking. Corrosion deposits and other contaminants gradually build up inside of the brake hydraulic sys. Check the bottom of the master-cylinder reservoir for a build up of fine black silt. If any is present the brake fluid should be flushed. - Never reuse brake fluid that has been drained from the brake system. DOT 3,4 or DOT 5 As a general rule DOT 5 brake fluid should not be used in vehicles recommending DOT 3 or 4 type fluid. DOT 5 brake fluid is silicone based. DOT 3 (standard) and DOT 4 (heavy-duty) are glycol-based. DOT 5 can be distinguished from conventional brake fluids by its purple color (which comes from a dye). DOT 5 silicone brake fluid won't mix with glycol-based brake fluid (creating concern over sludging if all old fluid isn't removed when a system is refilled with silicone). Silicone does not absorb moisture. DOT 5 brake fluid does not become contaminated with moisture over time as conventional DOT 3 and 4 brake fluids do. Silicone is also chemically inert, nontoxic and won't damage paint like conventional brake fluid. It also has a higher boiling point. Because of this, it is often marketed as a premium "lifetime" brake fluid. It is often used to preserve brake systems in antique vehicles and those that sit for long periods of time between use. Silicone also has slightly different physical properties and compressibility, making it unsuitable for ABS systems calibrated to work with DOT 3 or 4 brake fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 1397 Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures Brake System Bleeding The content of this article reflects the changes called out by TSB 05-01-94. The base brake system must be bled anytime air is permitted to enter the hydraulic system. However, anti-lock brake system components should only be bled if the hydraulic control unit has been removed or if there is reason to believe that air has entered the unit. The ABS portion of the braking system must be bled separately. Under most circumstances, only the base brake system will require bleeding. If the anti-lock brake system must be bled, proceed as follows: 1. Bleed base brake system, then remove battery, battery tray, support bracket and acid shield. 2. Using suitable jumper cables, reconnect battery to vehicle battery cables, then connect DRB scan tool to diagnostic connector. Use extreme caution to avoid arcs and shorts against vehicle body when battery is connected through cables. 3. Using DRB, ensure Controller Antilock Brake (CAB) has no stored diagnostic trouble codes. 4. Bleed modulator primary check valve circuit, then the secondary check valve circuit as follows: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 1398 Fig. 242 Primary Check Valve Circuit Bleed Screw Location Fig. 243 Secondary Check Valve Circuit Bleed Screw Location a. Connect clear bleed tube to check valve circuit bleed screw, then place other end of tube in a clear glass container partially filled with clean brake fluid. b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure while loosening check valve circuit bleed screw one full turn. c. When brake pedal bottoms, tighten bleed screw, then release pedal. Do not release pedal until bleed screw is tight. d. Repeat procedure until brake fluid flowing through tube appears bubble-free and clean, then torque modulator assembly secondary bleed screw Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 1399 to 80 in. lbs. Do not remove bleed hose before screw is tight. 5. Bleed modulator primary sump circuit as follows: Fig. 244 Primary Sump Circuit Bleed Screw Location a. Connect clear bleed tube to primary sump circuit bleed screw, then place other end of tube in a clear glass container partially filled with clean brake fluid. b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure while loosening primary sump circuit bleed screw one full turn. c. Using DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Primary Circuit." Right front and left rear solenoids will fire alternately for approximately five seconds. d. Continue to select "Primary Circuit" on DRB until brake fluid flowing through bleed tube is bubble-free or until brake pedal bottoms. e. If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure. f. Torque primary sump bleed screw to 80 in. lbs., then release brake pedal and remove bleed tube from screw. Do not release pedal until bleed screw is tight. 6. Bleed modulator assembly primary accumulator circuit as follows: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 1400 Fig. 245 Primary Accumulator Circuit Bleed Screw Location a. Connect clear bleed tube to primary accumulator circuit bleed screw, then place other end of tube in a clear glass container partially filled with clean brake fluid. b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure. c. Using DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Primary Circuit Valves." Right front and left rear solenoids will fire alternately for approximately five seconds. d. Loosen primary accumulator circuit bleed screw one full turn. e. Continue bleeding primary accumulator circuit until brake fluid flowing through bleed tube is bubble-free or until brake pedal bottoms. f. If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure. g. Tighten primary accumulator bleed screw, then release brake pedal. Do not release pedal until bleed screw is tight. h. Pump brake pedal repeatedly, then depress pedal and exert a constant heavy force while opening primary accumulator circuit bleed screw one full turn. i. Without using DRB or allowing modulator solenoids to fire, bleed primary accumulator circuit until brake fluid flowing through tube appears bubble-free and clean. j. When brake fluid appears as specified, torque primary accumulator bleed screw to 80 in. lbs. and release brake pedal. Do not release brake pedal until bleed screw is tight. 7. Bleed modulator assembly secondary sump circuit as follows: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 1401 Fig. 246 Secondary Sump Circuit Bleed Screw Location a. Connect clear bleed tube to secondary sump circuit bleed screw, then place other end of tube in a clear glass container partially filled with clean brake fluid. b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure while loosening secondary sump circuit bleed screw one full turn. c. Using DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Secondary Circuit Valves." Left front and right rear solenoids will fire alternately for approximately five seconds. d. Continue to select "Secondary Circuit Valves" on DRB until brake fluid flowing through bleed tube is bubble-free or until brake pedal bottoms. e. If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure. f. Torque secondary sump bleed screw to 80 in. lbs., then release brake pedal and remove bleed tube from screw. Do not release pedal until bleed screw is tight. 8. Bleed modulator assembly secondary accumulator circuit as follows: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 1402 Fig. 247 Secondary Accumulator Circuit Bleed Screw Location a. Connect clear bleed tube to secondary accumulator circuit bleed screw, then place other end of tube in a clear glass container partially filled with clean brake fluid. b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure. c. Using DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Secondary Circuit Valves." Left front and right rear solenoids will fire alternately for approximately five seconds. d. Loosen secondary accumulator circuit bleed screw one full turn. e. Continue bleeding secondary accumulator circuit until brake fluid flowing through bleed tube is bubble-free or until brake pedal bottoms. f. If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure. g. Tighten secondary accumulator bleed screw, then release brake pedal. Do not release pedal until bleed screw is tight. h. Pump brake pedal repeatedly, then depress pedal and exert a constant heavy force while opening secondary accumulator circuit bleed screw one full turn. i. Without using DRB or allowing modulator solenoids to fire, bleed secondary accumulator circuit until brake fluid flowing through tube appears bubble-free and clean. j. When brake fluid appears as specified, torque secondary accumulator bleed screw to 80 in. lbs. and release brake pedal. Do not release brake pedal until bleed screw is tight. 9. Remove bleed tube and container, then install battery acid shield, tray support bracket, tray and battery. Pressure Bleeding When bleeding ABS systems use only diaphragm type bleed pressure bleeder. 1. Turn ignition switch to Off position, then pump brake pedal a minimum of 40 times to de-pressurize hydraulic accumulator. 2. Attach bleeding equipment to brake reservoir. 3. Connect a suitable transparent hose to bleeder valve on left rear wheel cylinder and submerge other end in a glass container partially filled with clean brake fluid. 4. Turn pressure bleeder On, open brake bleed screw 3/4 to one turn. Allow brake fluid to flow until clear and bubble free. 5. Continue to bleed right rear, left front, then right front brakes in that order. 6. Turn Off pressure bleeder, then slowly bleed off pressure from equipment. 7. Remove pressure bleeder from vehicle, ensure proper fluid level in master cylinder. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 1403 Brake Bleeding: Service and Repair Pressure Bleeding (Preferred Procedure) When bleeding ABS systems use only diaphragm type bleed pressure bleeder. 1. On models with anti-lock brakes, turn ignition switch to Off position, then pump brake pedal a minimum of 40 times to de-pressurize hydraulic accumulator. 2. On all models, attach bleeding equipment to brake reservoir. 3. Connect a suitable transparent hose to bleeder valve on left rear wheel cylinder and submerge other end in a glass container partially filled with clean brake fluid. 4. Turn pressure bleeder On, then open brake bleed screw 3/4 to one turn. Allow brake fluid to flow until clear and bubble free. 5. Continue to bleed right rear, left front, then right front brakes in that order. 6. Turn Off pressure bleeder, then slowly bleed off pressure from equipment. 7. Remove pressure bleeder from vehicle, ensure proper fluid level in master cylinder. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least ten minutes after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 1408 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming ARMING 1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate SRS system is functioning correctly. 5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air Bag Systems/Testing and Inspection. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center Fuse: Locations Power Distribution Center Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center > Page 1414 Power Distribution Center (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center > Page 1415 Fig. 16 Fuse Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center > Page 1416 Fuse: Locations Fuse Block Module Fuseblock Module (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center > Page 1417 Fuseblock Module (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1420 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1421 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1422 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1423 Fuse: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1424 Fuse: Electrical Diagrams Fuse Application Chart (Part 1 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1425 Fuse Application Chart (Part 2 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1426 Fuse Application Chart (Part 3 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1427 Fuse Application Chart (Part 4 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Page 1428 Fuse: Service Precautions When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Technical Service Bulletins > Customer Interest for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle in Lower Left Dash Area Fuse Block: Customer Interest Fuse Block - Rattle in Lower Left Dash Area NO.: 08-46-93 Rev. A GROUP: Electrical DATE: Dec. 17, 1993 SUBJECT: Fuse Block Mounting Tabs Cracked THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-46-93 DATED OCT. 8, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS SPECIAL SERVICE ONLY REPAIR PARTS AND THE PROCEDURE TO INSTALL THEM. MODELS: 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 09/20/93 (MDH 092006). SYMPTOM/CONDITION: A rattle may be heard at the lower left area of the instrument panel. This condition can be caused by the mounting tabs of the fuse block cracking and coming loose from the mounting bracket. DIAGNOSIS: Inspect the fuse block for looseness and/or cracks at the mounting tabs. If cracks are discovered, perform the repair procedure. If no cracks are found, tighten the screws attaching the fuse block to 20 In.Lbs. (2.3 N-m). PARTS REQUIRED: 1 4773171 Bracket 1 4773172 Bracket REPAIR PROCEDURE: This bulletin involves installing revised fuse block mounting brackets. 1. Using the procedure outlined starting on Page 8E-17 of the 1994 Town & Country/Caravan/Voyager Service Manual (Publication No. 81-3704105), remove the steering column cover. 2. Remove the two screws attaching the fuse block bracket to the instrument panel bracing. 3. Remove the two screws attaching the bracket to the fuse block. Discard the bracket. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Technical Service Bulletins > Customer Interest for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle in Lower Left Dash Area > Page 1437 4. Using the two screws that attached the original bracket to the fuse block, assemble the service brackets (P/N 4773171 and P/N 4773172) to the fuse block as shown in the illustration. Tighten the screws to 20 In.Lbs. (2.3 N-m). 6. Reverse steps 1 through 3 to reinstall the fuse block. Use the original screws and tighten them to 20 In.Lbs. (2.3 N-m). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-90-92 0.3 Hrs. FAILURE CODE: 11 - Broken or Cracked Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle in Lower Left Dash Area Fuse Block: All Technical Service Bulletins Fuse Block - Rattle in Lower Left Dash Area NO.: 08-46-93 Rev. A GROUP: Electrical DATE: Dec. 17, 1993 SUBJECT: Fuse Block Mounting Tabs Cracked THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-46-93 DATED OCT. 8, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS SPECIAL SERVICE ONLY REPAIR PARTS AND THE PROCEDURE TO INSTALL THEM. MODELS: 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 09/20/93 (MDH 092006). SYMPTOM/CONDITION: A rattle may be heard at the lower left area of the instrument panel. This condition can be caused by the mounting tabs of the fuse block cracking and coming loose from the mounting bracket. DIAGNOSIS: Inspect the fuse block for looseness and/or cracks at the mounting tabs. If cracks are discovered, perform the repair procedure. If no cracks are found, tighten the screws attaching the fuse block to 20 In.Lbs. (2.3 N-m). PARTS REQUIRED: 1 4773171 Bracket 1 4773172 Bracket REPAIR PROCEDURE: This bulletin involves installing revised fuse block mounting brackets. 1. Using the procedure outlined starting on Page 8E-17 of the 1994 Town & Country/Caravan/Voyager Service Manual (Publication No. 81-3704105), remove the steering column cover. 2. Remove the two screws attaching the fuse block bracket to the instrument panel bracing. 3. Remove the two screws attaching the bracket to the fuse block. Discard the bracket. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle in Lower Left Dash Area > Page 1443 4. Using the two screws that attached the original bracket to the fuse block, assemble the service brackets (P/N 4773171 and P/N 4773172) to the fuse block as shown in the illustration. Tighten the screws to 20 In.Lbs. (2.3 N-m). 6. Reverse steps 1 through 3 to reinstall the fuse block. Use the original screws and tighten them to 20 In.Lbs. (2.3 N-m). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-90-92 0.3 Hrs. FAILURE CODE: 11 - Broken or Cracked Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Technical Service Bulletins > Page 1444 Fuse Block: Locations Fuse panel is located below left side of instrument panel. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1447 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1448 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1449 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1450 Fuse Block: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1451 Fuse Block: Electrical Diagrams Fuse Application Chart (Part 1 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1452 Fuse Application Chart (Part 2 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1453 Fuse Application Chart (Part 3 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1454 Fuse Application Chart (Part 4 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1455 Power Distribution Center (Part 1 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1456 Power Distribution Center (Part 2 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1457 Power Distribution Center (Part 3 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1458 Power Distribution Center (Part 4 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1459 Fuse Block: Mechanical Diagrams Fig. 16 Fuse Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1460 Fuseblock Module (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1461 Fuseblock Module (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1462 Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1463 Power Distribution Center (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Service and Repair Fusible Link: Service and Repair Purpose Fusible links protect vehicle electrical systems from damage due to excessive current. ^ The most common cause of excessive current is a short to ground caused by a component or wiring failure. Fusible links are color coded to indicate wire gauge and size. Fig. 9 Fusible Link Chart CAUTION: Replace blown fusible links with correct gauge, hypalon insulated, fusible type wire ONLY. ^ Use of standard wire may result in severe damage to the electrical system or an electrical fire. NOTE: Refer to the fusible link chart and the wiring diagrams for proper color and gauge identification. Replacement Splicing Wires CAUTION: If a fusible link has blown, find the cause before attempting to replace the link. NOTE: If a faulty fusible link is suspected, it is important to carefully check the link for continuity over its entire length. In some instances the link may look fine and actually be blown. 1. Disconnect battery negative cable. 2. Cut out the blown portion of the fusible link. 3. Strip 1 inch of insulation from each end of the existing fusible link. 4. Place a piece of heat shrink tubing long enough to cover and seal the entire repair area over one side of the fusible link. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Service and Repair > Page 1467 5. Cut a replacement piece of fusible link approximately two inches longer than the piece removed. 6. Remove one inch of insulation from each end of the replacement fusible link. 7. Spread the stripped ends of the wires apart (example 1). 8. Push the stripped ends of the wires together until the cut ends almost touch the insulation of the other wire (example 2). 9. Twist the wires together (example 3). 10. Solder the wires together using rosin core type solder only. Never use acid core type solder for soldering electrical/electronic connections. 11. Center the heat shrink tubing over the joint. Heat the joint with a heat gun until the tubing is tightly sealed and sealant is coming out of both ends of the tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 1472 Micro Relay Block: Locations Power Distribution Center Identification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 1473 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 1474 Fig. 17 Relay Bank Identification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 1475 Micro Relay Block: Locations Micro Relay Block and Relay Bank Location Relay Bank is located near the fuse box and Micro Relay Bank is located behind center of instrument panel. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions Micro Relay Block: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 1478 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 1479 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 1480 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 1481 Micro Relay Block: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 1482 Micro Relay Block: Connector Views Micro Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 1483 Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 1484 Micro Relay Block: Electrical Diagrams Power Distribution Center (Part 1 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 1485 Power Distribution Center (Part 2 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 1486 Power Distribution Center (Part 3 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 1487 Power Distribution Center (Part 4 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Service Reminder Indicator Light <--> [Emissions Maintenance Light] > Component Information > Description and Operation Service Reminder Indicator Light: Description and Operation This Emission Maintenance Reminder System is incorporated into the engine controller. The controller stores vehicle mileage into its memory every 8 miles, then at 60,000, 82,500 or 120,000 miles it will illuminate the Emission Maintenance Reminder (EMR) lamp. When the indicated mileage is reached or the EMR lamp is on at all times, the following parts must be replaced and the EMR lamp reset. After necessary emission maintenance has been performed, connect Diagnosis Read-Out Box II (DRB II) to the on-board diagnosis connector. Follow instructions indicated by DRB II tool. 1. At 60,00 miles, proceed as follows: a. Replace EGR valve. b. Clean EGR passage. c. Replace PCV valve. 2. At 82,500 miles, proceed as follows: a. Replace oxygen sensor. 3. At 120,000 miles, proceed as follows: a. Replace EGR valve. b. Clean EGR passage. c. Replace PCV valve. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Locations Malfunction Indicator Lamp: Locations NOTE: MIL previously called Check Engine Lamp (CEL). Light in instrument panel. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Locations > Page 1495 Malfunction Indicator Lamp: Description and Operation NOTE: Malfunction Indicator Lamp (MIL), previously called Check Engine Lamp (CEL). PURPOSE Indicates immediate service of engine control system is required. Informs driver that he has entered "Limp-In" mode, lamp ON while vehicle is being driven. Displays Diagnostic Trouble Codes (DTC's), stored in memory. OPERATION Illuminates for three seconds when ignition switch is turned ON, (for bulb test). Illuminates if Powertrain Control Module (PCM) receives an out of range input from a monitored circuit, or, (for vehicles with California emissions), from an emission related device. - Signals that can set Malfunction Indicator Lamp are battery voltage input, charging system, Manifold Absolute Pressure (MAP), sensor, Throttle Position Sensor (TPS), Engine Coolant Temperature (ECT) sensor. Can be used to display any DTC's stored in memory, SEE POWERTRAIN MANAGEMENT/COMPUTERS AND CONTROL SYSTEMS/TESTING AND INSPECTION. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Locations Fig. 1 Caravan, Town & Country & Voyager Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. Technical Service Bulletin # 22-03-99 Date: 990423 Tires/Wheels - Smooth Road Vibration/Shake/Wobble. NUMBER: 22-03-99 GROUP: Wheels & Tires DATE: April 23, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: Smooth Road Vibration/Shake/Wobble OVERVIEW: This bulletin involves diagnosis and correction information for vehicles with a smooth road high-speed vibration or shake condition. Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph) is addressed by TSB 22-02-99. Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with 3.0L engine and 31TH transaxle is addressed by TSB 19-04-97. High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph). MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) EQUIPMENT REQUIRED: Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer (Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper POLICY: Information Only Diagnosis and Correction Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a hoist and inspect the following items: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1511 VISUAL INSPECTION Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road surface with all accessories turned off. Correct any obvious safety related items identified during the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components. If the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration problem is still present make the following checks: ^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the Service Manual. ^ If the vibration does not change while coasting then the problem may be caused by tires, wheels or suspension. ^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of rotating components (tires, wheels, half shafts, drums or rotors). ^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel assembly run out. ^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel assembly. ^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer to the Service Manual. ^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may be caused by high 1st order tire/wheel assembly excitation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1512 ON CAR TIRE/WHEEL ASSEMBLY RUNOUT After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration is still present and it was determined that the vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure. Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of reducing runout. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1513 TIRE/WHEEL MATCH MOUNTING Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1514 WHEEL RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1515 WHEEL BORE PILOT DIAMETERS Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1516 HUB WHEEL PILOT DIAMETER Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1517 HUB WHEEL PILOT RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1518 WHEEL MOUNTING SURFACE LATERAL RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. Technical Service Bulletin # 22-03-99 Date: 990423 Tires/Wheels - Smooth Road Vibration/Shake/Wobble. NUMBER: 22-03-99 GROUP: Wheels & Tires DATE: April 23, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: Smooth Road Vibration/Shake/Wobble OVERVIEW: This bulletin involves diagnosis and correction information for vehicles with a smooth road high-speed vibration or shake condition. Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph) is addressed by TSB 22-02-99. Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with 3.0L engine and 31TH transaxle is addressed by TSB 19-04-97. High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph). MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) EQUIPMENT REQUIRED: Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer (Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper POLICY: Information Only Diagnosis and Correction Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a hoist and inspect the following items: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1524 VISUAL INSPECTION Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road surface with all accessories turned off. Correct any obvious safety related items identified during the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components. If the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration problem is still present make the following checks: ^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the Service Manual. ^ If the vibration does not change while coasting then the problem may be caused by tires, wheels or suspension. ^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of rotating components (tires, wheels, half shafts, drums or rotors). ^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel assembly run out. ^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel assembly. ^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer to the Service Manual. ^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may be caused by high 1st order tire/wheel assembly excitation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1525 ON CAR TIRE/WHEEL ASSEMBLY RUNOUT After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration is still present and it was determined that the vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure. Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of reducing runout. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1526 TIRE/WHEEL MATCH MOUNTING Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1527 WHEEL RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1528 WHEEL BORE PILOT DIAMETERS Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1529 HUB WHEEL PILOT DIAMETER Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1530 HUB WHEEL PILOT RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1531 WHEEL MOUNTING SURFACE LATERAL RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout Tires: All Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake Tires: All Technical Service Bulletins Tires/Wheels - Smooth Road Vibration/Shake NO: 22-02-94 GROUP: Wheels & Tires DATE: Feb.18, 1994 SUBJECT: Smooth Road Vibration/Shake MODELS: 1992 - 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: A smooth road vibration/shake condition may be observed on smooth roads as: - Low speed lateral wobble of the body (0-30 MPH) - Steering wheel/seat/floor pan vibration at high speeds (60+ MPH) Use the following flow chart for diagnosis and correction: DYNAMIC CHECK Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of vibration/shake condition. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1540 VISUAL INSPECTION (See illustration) TIRE/WHEEL/HUB RUNOUT CHECKS NOTE: ENSURE THE WHEEL BEARINGS ARE PROPERLY ADJUSTED BEFORE PROCEEDING. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1541 Use a dial indicator to check the radial and lateral tire/wheel runouts on vehicle (refer to Figure 1). Mark the point of maximum radial and lateral runout on the tires/wheels. SPECIFICATIONS: Radial runout: 0.030 in. (0.762 mm) or LESS Lateral runout: 0.030 in. (0.762 mm) or LESS Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1542 Mark the tire AND wheel at the point of highest runout. Remove the tire from the wheel and check the wheel runouts (check BOTH sides of the wheel at the bead seats (refer to Figure 2) with wheel mounted on an off car balancer. SPECIFICATIONS: Radial runout: 0.030 in. (0.762 mm) or LESS Lateral runout: 0.030 in. (0.762 mm) or LESS NOTE: HUB MEASUREMENTS APPLY TO FRONT HUBS ONLY ON FRONT WHEEL DRIVE (FWD) VEHICLES AND TO FRONT AND REAR HUBS ON ALL WHEEL DRIVE (AWD) VEHICLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1543 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1544 Measure hub wheel pilot diameter (refer to Figure 4). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout Tires: All Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake Tires: All Technical Service Bulletins Tires/Wheels - Smooth Road Vibration/Shake NO: 22-02-94 GROUP: Wheels & Tires DATE: Feb.18, 1994 SUBJECT: Smooth Road Vibration/Shake MODELS: 1992 - 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: A smooth road vibration/shake condition may be observed on smooth roads as: - Low speed lateral wobble of the body (0-30 MPH) - Steering wheel/seat/floor pan vibration at high speeds (60+ MPH) Use the following flow chart for diagnosis and correction: DYNAMIC CHECK Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of vibration/shake condition. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1554 VISUAL INSPECTION (See illustration) TIRE/WHEEL/HUB RUNOUT CHECKS NOTE: ENSURE THE WHEEL BEARINGS ARE PROPERLY ADJUSTED BEFORE PROCEEDING. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1555 Use a dial indicator to check the radial and lateral tire/wheel runouts on vehicle (refer to Figure 1). Mark the point of maximum radial and lateral runout on the tires/wheels. SPECIFICATIONS: Radial runout: 0.030 in. (0.762 mm) or LESS Lateral runout: 0.030 in. (0.762 mm) or LESS Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1556 Mark the tire AND wheel at the point of highest runout. Remove the tire from the wheel and check the wheel runouts (check BOTH sides of the wheel at the bead seats (refer to Figure 2) with wheel mounted on an off car balancer. SPECIFICATIONS: Radial runout: 0.030 in. (0.762 mm) or LESS Lateral runout: 0.030 in. (0.762 mm) or LESS NOTE: HUB MEASUREMENTS APPLY TO FRONT HUBS ONLY ON FRONT WHEEL DRIVE (FWD) VEHICLES AND TO FRONT AND REAR HUBS ON ALL WHEEL DRIVE (AWD) VEHICLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1557 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1558 Measure hub wheel pilot diameter (refer to Figure 4). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels Wheels: Recalls Recall - Stamped Steel Road Wheels No. 603 January, 1994 To: All Dodge and Chrysler-Plymouth Dealers Subject: Safety Recall # 603 -- Stamped Steel Road Wheels Models: 1994 Model Year Dodge Grand Caravan, Plymouth Grand Voyager and Chrysler Town and Country Vehicles Built on September 23 and 24, 1993 and Equipped with 15" Stamped Steel Wheels and/or a 15" Full Size Stamped Steel Spare. The nut seat of the stamped steel road wheel may be misformed and result in the loss of lug nut torque retention. To correct the condition, all wheels must be inspected for an "M1" manufacturing plant code and all suspect wheels must be replaced. Less than 100 vehicles are involved in this recall. IMPORTANT: Some of the involved vehicles may be in dealer inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by Certified Mail. Important: Dealer notification by Certified Mail is required by federal law for all safety recalls. Responsible dealership personnel should be instructed to sign for this Certified Mail without hesitation as it concerns urgent safety recall information. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. All dealers: Each Dodge and Chrysler-Plymouth dealer will receive a copy of this dealer recall notification letter by Compak mail. DIAL System Function 70 All involved vehicles will be entered to DIAL System Function 70 at the time of recall implementation for dealer inquiry by VIN as needed. Parts Important: Due to the small number of involved vehicles and the unknown number of wheels required for each vehicle, no parts will be distributed initially to dealers. Dealers are requested to order parts only to support scheduled repairs. Wheel Packages, Recall PN C3905750, may be ordered at dealer cost to support customer demand. Owners were requested to inspect their vehicle to determine the number of replacement wheels required. Dealers should inquire if the owner performed the inspection and order the required parts when scheduling the service appointment. Each parts package contains the components (see illustration). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 1567 Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to inspect wheels for the suspect manufacturing plant code and/or schedule appointments for the service with their dealers at the earliest possible date. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure A. Inspect Wheel Manufacturing Plant Code: NOTE: Vehicle may have one, four or five wheels to be inspected. A1. FOR VEHICLES EQUIPPED WITH 15" STAMPED STEEL WHEELS (Sales Code WCF): a. Remove all wheel covers. b. Inspect wheel manufacturing plant code located above valve stem (Figure 1). NOTE: Manufacturing plant code may be covered by a green sticker. Remove and discard sticker as necessary. A2. FOR VEHICLES EQUIPPED WITH 15" FULL SIZE STAMPED STEEL SPARE (Sales Code -TBB): a. Gain access to spare. b. Inspect wheel manufacturing plant code located above valve stem (Figure 1). NOTE: Manufacturing plant code may be covered by a green sticker. Remove and discard sticker as necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 1568 A3. If any of the wheels inspected contain a Manufacturing Plant Code of M1, replace the affected wheel as instructed in Section B. If none of the wheels have the M1 plant code, reinstall wheel covers and/or secure spare, no further action is required. NOTE: Replace only those wheels having the M1 plant code. B. Replace Wheel: B1. Remove all wheels with suspect M1 plant code. Discard lug nuts. B2. Remove tire(s) from wheel(s). Set wheel(s) aside for return to Warranty Material Return Center. B3. Install supplied valve stem(s). B4. Mount and balance tire(s) on supplied wheel(s). B5. Install wheel and tire assembly on vehicle using supplied lug nuts. Tighten lug nuts to 95 ft.lbs. (130 N-m) torque. B6. Reinstall wheel cover(s) and/or secure spare. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances (see illustration). Add the cost of any recall parts packages used plus applicable dealer allowance to your claim. Parts Return Removed wheels must be returned to the Warranty Material Return Center. Note: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation 429-10-04 P.O. Box 1919 Detroit, Michigan 48231-1919 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 1569 SAFETY RECALL -- Stamped Steel Road Wheels Dear Chrysler Corporation Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1994 model Dodge Grand Caravan, Chrysler Town & Country and Plymouth Grand Voyager vehicles. The lug nuts attaching the stamped steel road wheels may loosen and result in a wheel becoming loose. This could result in an accident without prior warning. Your vehicle, identified on the enclosed form, is affected. For this reason we ask that you arrange for service to correct the condition without delay. The service and required parts as described in this letter will be provided free of charge. The stamped steel road wheel lug nut seats may have been misformed with an incorrect taper, which can result in loosening of the lug nuts. These wheels were used on vehicles equipped with 15" wheels with full wheel covers and also for 15" full size spare tires. You may inspect for suspect wheels yourself. Please refer to the instructions on the reverse side of this letter for details. If no suspect wheels are found, no further action is necessary. Please mark "INSPECTED -- OK" on the pre-addressed Vehicle Disposition Form portion of the enclosed owner notification form and put it in the mail. No postage is required. If you prefer not to do the inspection yourself, your dealer will do the inspection for you. To correct the condition, your dealer will inspect the manufacturing plant code of all steel wheels and replace any suspect wheels. The inspection will take less than one-half hour to complete. However, additional time may be required depending on how many wheels require replacement and how dealer appointments are scheduled and processed. To obtain this free service: ^ Contact your dealer as soon as possible to schedule an appointment for the service. If you performed the wheel inspection, be sure to inform your dealer of the number of suspect wheels found on your vehicle so the proper quantity of replacement wheels is ordered prior to your service appointment. ^ Take the enclosed Owner Notification Form with you at the time of your appointment and give it to your dealer. The form identifies the vehicle and the service that is required. If you have any problem obtaining the needed repair, please call the Chrysler Customer Center, toll free, at (800) 992-1997. A representative will assist you in getting your vehicle repaired. We regret any inconvenience which this action may cause you. However, we are concerned about your safety. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington D.C. area residents may call 366-0123.) Thank you for your attention to this important matter. STAMPED STEEL WHEEL INSPECTION INSTRUCTIONS 1994 DODGE GRAND CARAVAN, PLYMOUTH GRAND VOYAGER AND CHRYSLER TOWN & COUNTRY FOR VEHICLES EQUIPPED WITH 15" STAMPED STEEL WHEELS: ^ Remove all wheel covers. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 1570 ^ Inspect wheel manufacturing plant code located above valve stem as shown. ^ Reinstall wheel covers. FOR VEHICLES EQUIPPED WITH A 15" STAMPED STEEL WHEEL FULL SIZE SPARE: Gain access to spare following the instructions in your Owner's Manual. Inspect wheel manufacturing plant code located above valve stem as shown. If any of the wheels inspected contain a manufacturing plant code of M1, make an appointment with your dealer to have the suspect wheel(s) replaced. NOTE: Plant code may be covered by a green sticker. Remove and discard sticker as necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. Technical Service Bulletin # 22-03-99 Date: 990423 Tires/Wheels - Smooth Road Vibration/Shake/Wobble. NUMBER: 22-03-99 GROUP: Wheels & Tires DATE: April 23, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: Smooth Road Vibration/Shake/Wobble OVERVIEW: This bulletin involves diagnosis and correction information for vehicles with a smooth road high-speed vibration or shake condition. Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph) is addressed by TSB 22-02-99. Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with 3.0L engine and 31TH transaxle is addressed by TSB 19-04-97. High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph). MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) EQUIPMENT REQUIRED: Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer (Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper POLICY: Information Only Diagnosis and Correction Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a hoist and inspect the following items: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1576 VISUAL INSPECTION Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road surface with all accessories turned off. Correct any obvious safety related items identified during the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components. If the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration problem is still present make the following checks: ^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the Service Manual. ^ If the vibration does not change while coasting then the problem may be caused by tires, wheels or suspension. ^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of rotating components (tires, wheels, half shafts, drums or rotors). ^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel assembly run out. ^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel assembly. ^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer to the Service Manual. ^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may be caused by high 1st order tire/wheel assembly excitation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1577 ON CAR TIRE/WHEEL ASSEMBLY RUNOUT After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration is still present and it was determined that the vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure. Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of reducing runout. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1578 TIRE/WHEEL MATCH MOUNTING Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1579 WHEEL RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1580 WHEEL BORE PILOT DIAMETERS Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1581 HUB WHEEL PILOT DIAMETER Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1582 HUB WHEEL PILOT RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1583 WHEEL MOUNTING SURFACE LATERAL RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. Technical Service Bulletin # 22-03-99 Date: 990423 Tires/Wheels - Smooth Road Vibration/Shake/Wobble. NUMBER: 22-03-99 GROUP: Wheels & Tires DATE: April 23, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: Smooth Road Vibration/Shake/Wobble OVERVIEW: This bulletin involves diagnosis and correction information for vehicles with a smooth road high-speed vibration or shake condition. Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph) is addressed by TSB 22-02-99. Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with 3.0L engine and 31TH transaxle is addressed by TSB 19-04-97. High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph). MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) EQUIPMENT REQUIRED: Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer (Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper POLICY: Information Only Diagnosis and Correction Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a hoist and inspect the following items: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1589 VISUAL INSPECTION Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road surface with all accessories turned off. Correct any obvious safety related items identified during the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components. If the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration problem is still present make the following checks: ^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the Service Manual. ^ If the vibration does not change while coasting then the problem may be caused by tires, wheels or suspension. ^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of rotating components (tires, wheels, half shafts, drums or rotors). ^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel assembly run out. ^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel assembly. ^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer to the Service Manual. ^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may be caused by high 1st order tire/wheel assembly excitation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1590 ON CAR TIRE/WHEEL ASSEMBLY RUNOUT After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration is still present and it was determined that the vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure. Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of reducing runout. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1591 TIRE/WHEEL MATCH MOUNTING Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1592 WHEEL RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1593 WHEEL BORE PILOT DIAMETERS Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1594 HUB WHEEL PILOT DIAMETER Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1595 HUB WHEEL PILOT RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1596 WHEEL MOUNTING SURFACE LATERAL RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout Wheels: All Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake Wheels: All Technical Service Bulletins Tires/Wheels - Smooth Road Vibration/Shake NO: 22-02-94 GROUP: Wheels & Tires DATE: Feb.18, 1994 SUBJECT: Smooth Road Vibration/Shake MODELS: 1992 - 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: A smooth road vibration/shake condition may be observed on smooth roads as: - Low speed lateral wobble of the body (0-30 MPH) - Steering wheel/seat/floor pan vibration at high speeds (60+ MPH) Use the following flow chart for diagnosis and correction: DYNAMIC CHECK Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of vibration/shake condition. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1605 VISUAL INSPECTION (See illustration) TIRE/WHEEL/HUB RUNOUT CHECKS NOTE: ENSURE THE WHEEL BEARINGS ARE PROPERLY ADJUSTED BEFORE PROCEEDING. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1606 Use a dial indicator to check the radial and lateral tire/wheel runouts on vehicle (refer to Figure 1). Mark the point of maximum radial and lateral runout on the tires/wheels. SPECIFICATIONS: Radial runout: 0.030 in. (0.762 mm) or LESS Lateral runout: 0.030 in. (0.762 mm) or LESS Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1607 Mark the tire AND wheel at the point of highest runout. Remove the tire from the wheel and check the wheel runouts (check BOTH sides of the wheel at the bead seats (refer to Figure 2) with wheel mounted on an off car balancer. SPECIFICATIONS: Radial runout: 0.030 in. (0.762 mm) or LESS Lateral runout: 0.030 in. (0.762 mm) or LESS NOTE: HUB MEASUREMENTS APPLY TO FRONT HUBS ONLY ON FRONT WHEEL DRIVE (FWD) VEHICLES AND TO FRONT AND REAR HUBS ON ALL WHEEL DRIVE (AWD) VEHICLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1608 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1609 Measure hub wheel pilot diameter (refer to Figure 4). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels Wheels: All Technical Service Bulletins Recall - Stamped Steel Road Wheels No. 603 January, 1994 To: All Dodge and Chrysler-Plymouth Dealers Subject: Safety Recall # 603 -- Stamped Steel Road Wheels Models: 1994 Model Year Dodge Grand Caravan, Plymouth Grand Voyager and Chrysler Town and Country Vehicles Built on September 23 and 24, 1993 and Equipped with 15" Stamped Steel Wheels and/or a 15" Full Size Stamped Steel Spare. The nut seat of the stamped steel road wheel may be misformed and result in the loss of lug nut torque retention. To correct the condition, all wheels must be inspected for an "M1" manufacturing plant code and all suspect wheels must be replaced. Less than 100 vehicles are involved in this recall. IMPORTANT: Some of the involved vehicles may be in dealer inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by Certified Mail. Important: Dealer notification by Certified Mail is required by federal law for all safety recalls. Responsible dealership personnel should be instructed to sign for this Certified Mail without hesitation as it concerns urgent safety recall information. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. All dealers: Each Dodge and Chrysler-Plymouth dealer will receive a copy of this dealer recall notification letter by Compak mail. DIAL System Function 70 All involved vehicles will be entered to DIAL System Function 70 at the time of recall implementation for dealer inquiry by VIN as needed. Parts Important: Due to the small number of involved vehicles and the unknown number of wheels required for each vehicle, no parts will be distributed initially to dealers. Dealers are requested to order parts only to support scheduled repairs. Wheel Packages, Recall PN C3905750, may be ordered at dealer cost to support customer demand. Owners were requested to inspect their vehicle to determine the number of replacement wheels required. Dealers should inquire if the owner performed the inspection and order the required parts when scheduling the service appointment. Each parts package contains the components (see illustration). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 1614 Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to inspect wheels for the suspect manufacturing plant code and/or schedule appointments for the service with their dealers at the earliest possible date. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure A. Inspect Wheel Manufacturing Plant Code: NOTE: Vehicle may have one, four or five wheels to be inspected. A1. FOR VEHICLES EQUIPPED WITH 15" STAMPED STEEL WHEELS (Sales Code WCF): a. Remove all wheel covers. b. Inspect wheel manufacturing plant code located above valve stem (Figure 1). NOTE: Manufacturing plant code may be covered by a green sticker. Remove and discard sticker as necessary. A2. FOR VEHICLES EQUIPPED WITH 15" FULL SIZE STAMPED STEEL SPARE (Sales Code -TBB): a. Gain access to spare. b. Inspect wheel manufacturing plant code located above valve stem (Figure 1). NOTE: Manufacturing plant code may be covered by a green sticker. Remove and discard sticker as necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 1615 A3. If any of the wheels inspected contain a Manufacturing Plant Code of M1, replace the affected wheel as instructed in Section B. If none of the wheels have the M1 plant code, reinstall wheel covers and/or secure spare, no further action is required. NOTE: Replace only those wheels having the M1 plant code. B. Replace Wheel: B1. Remove all wheels with suspect M1 plant code. Discard lug nuts. B2. Remove tire(s) from wheel(s). Set wheel(s) aside for return to Warranty Material Return Center. B3. Install supplied valve stem(s). B4. Mount and balance tire(s) on supplied wheel(s). B5. Install wheel and tire assembly on vehicle using supplied lug nuts. Tighten lug nuts to 95 ft.lbs. (130 N-m) torque. B6. Reinstall wheel cover(s) and/or secure spare. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances (see illustration). Add the cost of any recall parts packages used plus applicable dealer allowance to your claim. Parts Return Removed wheels must be returned to the Warranty Material Return Center. Note: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation 429-10-04 P.O. Box 1919 Detroit, Michigan 48231-1919 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 1616 SAFETY RECALL -- Stamped Steel Road Wheels Dear Chrysler Corporation Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1994 model Dodge Grand Caravan, Chrysler Town & Country and Plymouth Grand Voyager vehicles. The lug nuts attaching the stamped steel road wheels may loosen and result in a wheel becoming loose. This could result in an accident without prior warning. Your vehicle, identified on the enclosed form, is affected. For this reason we ask that you arrange for service to correct the condition without delay. The service and required parts as described in this letter will be provided free of charge. The stamped steel road wheel lug nut seats may have been misformed with an incorrect taper, which can result in loosening of the lug nuts. These wheels were used on vehicles equipped with 15" wheels with full wheel covers and also for 15" full size spare tires. You may inspect for suspect wheels yourself. Please refer to the instructions on the reverse side of this letter for details. If no suspect wheels are found, no further action is necessary. Please mark "INSPECTED -- OK" on the pre-addressed Vehicle Disposition Form portion of the enclosed owner notification form and put it in the mail. No postage is required. If you prefer not to do the inspection yourself, your dealer will do the inspection for you. To correct the condition, your dealer will inspect the manufacturing plant code of all steel wheels and replace any suspect wheels. The inspection will take less than one-half hour to complete. However, additional time may be required depending on how many wheels require replacement and how dealer appointments are scheduled and processed. To obtain this free service: ^ Contact your dealer as soon as possible to schedule an appointment for the service. If you performed the wheel inspection, be sure to inform your dealer of the number of suspect wheels found on your vehicle so the proper quantity of replacement wheels is ordered prior to your service appointment. ^ Take the enclosed Owner Notification Form with you at the time of your appointment and give it to your dealer. The form identifies the vehicle and the service that is required. If you have any problem obtaining the needed repair, please call the Chrysler Customer Center, toll free, at (800) 992-1997. A representative will assist you in getting your vehicle repaired. We regret any inconvenience which this action may cause you. However, we are concerned about your safety. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington D.C. area residents may call 366-0123.) Thank you for your attention to this important matter. STAMPED STEEL WHEEL INSPECTION INSTRUCTIONS 1994 DODGE GRAND CARAVAN, PLYMOUTH GRAND VOYAGER AND CHRYSLER TOWN & COUNTRY FOR VEHICLES EQUIPPED WITH 15" STAMPED STEEL WHEELS: ^ Remove all wheel covers. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 1617 ^ Inspect wheel manufacturing plant code located above valve stem as shown. ^ Reinstall wheel covers. FOR VEHICLES EQUIPPED WITH A 15" STAMPED STEEL WHEEL FULL SIZE SPARE: Gain access to spare following the instructions in your Owner's Manual. Inspect wheel manufacturing plant code located above valve stem as shown. If any of the wheels inspected contain a manufacturing plant code of M1, make an appointment with your dealer to have the suspect wheel(s) replaced. NOTE: Plant code may be covered by a green sticker. Remove and discard sticker as necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. Technical Service Bulletin # 22-03-99 Date: 990423 Tires/Wheels - Smooth Road Vibration/Shake/Wobble. NUMBER: 22-03-99 GROUP: Wheels & Tires DATE: April 23, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: Smooth Road Vibration/Shake/Wobble OVERVIEW: This bulletin involves diagnosis and correction information for vehicles with a smooth road high-speed vibration or shake condition. Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph) is addressed by TSB 22-02-99. Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with 3.0L engine and 31TH transaxle is addressed by TSB 19-04-97. High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph). MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) EQUIPMENT REQUIRED: Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer (Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper POLICY: Information Only Diagnosis and Correction Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a hoist and inspect the following items: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1623 VISUAL INSPECTION Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road surface with all accessories turned off. Correct any obvious safety related items identified during the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components. If the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration problem is still present make the following checks: ^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the Service Manual. ^ If the vibration does not change while coasting then the problem may be caused by tires, wheels or suspension. ^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of rotating components (tires, wheels, half shafts, drums or rotors). ^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel assembly run out. ^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel assembly. ^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer to the Service Manual. ^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may be caused by high 1st order tire/wheel assembly excitation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1624 ON CAR TIRE/WHEEL ASSEMBLY RUNOUT After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration is still present and it was determined that the vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure. Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of reducing runout. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1625 TIRE/WHEEL MATCH MOUNTING Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1626 WHEEL RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1627 WHEEL BORE PILOT DIAMETERS Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1628 HUB WHEEL PILOT DIAMETER Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1629 HUB WHEEL PILOT RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1630 WHEEL MOUNTING SURFACE LATERAL RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout Wheels: All Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake Wheels: All Technical Service Bulletins Tires/Wheels - Smooth Road Vibration/Shake NO: 22-02-94 GROUP: Wheels & Tires DATE: Feb.18, 1994 SUBJECT: Smooth Road Vibration/Shake MODELS: 1992 - 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: A smooth road vibration/shake condition may be observed on smooth roads as: - Low speed lateral wobble of the body (0-30 MPH) - Steering wheel/seat/floor pan vibration at high speeds (60+ MPH) Use the following flow chart for diagnosis and correction: DYNAMIC CHECK Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of vibration/shake condition. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1639 VISUAL INSPECTION (See illustration) TIRE/WHEEL/HUB RUNOUT CHECKS NOTE: ENSURE THE WHEEL BEARINGS ARE PROPERLY ADJUSTED BEFORE PROCEEDING. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1640 Use a dial indicator to check the radial and lateral tire/wheel runouts on vehicle (refer to Figure 1). Mark the point of maximum radial and lateral runout on the tires/wheels. SPECIFICATIONS: Radial runout: 0.030 in. (0.762 mm) or LESS Lateral runout: 0.030 in. (0.762 mm) or LESS Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1641 Mark the tire AND wheel at the point of highest runout. Remove the tire from the wheel and check the wheel runouts (check BOTH sides of the wheel at the bead seats (refer to Figure 2) with wheel mounted on an off car balancer. SPECIFICATIONS: Radial runout: 0.030 in. (0.762 mm) or LESS Lateral runout: 0.030 in. (0.762 mm) or LESS NOTE: HUB MEASUREMENTS APPLY TO FRONT HUBS ONLY ON FRONT WHEEL DRIVE (FWD) VEHICLES AND TO FRONT AND REAR HUBS ON ALL WHEEL DRIVE (AWD) VEHICLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1642 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1643 Measure hub wheel pilot diameter (refer to Figure 4). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1653 VISUAL INSPECTION (See illustration) TIRE/WHEEL/HUB RUNOUT CHECKS NOTE: ENSURE THE WHEEL BEARINGS ARE PROPERLY ADJUSTED BEFORE PROCEEDING. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1654 Use a dial indicator to check the radial and lateral tire/wheel runouts on vehicle (refer to Figure 1). Mark the point of maximum radial and lateral runout on the tires/wheels. SPECIFICATIONS: Radial runout: 0.030 in. (0.762 mm) or LESS Lateral runout: 0.030 in. (0.762 mm) or LESS Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1655 Mark the tire AND wheel at the point of highest runout. Remove the tire from the wheel and check the wheel runouts (check BOTH sides of the wheel at the bead seats (refer to Figure 2) with wheel mounted on an off car balancer. SPECIFICATIONS: Radial runout: 0.030 in. (0.762 mm) or LESS Lateral runout: 0.030 in. (0.762 mm) or LESS NOTE: HUB MEASUREMENTS APPLY TO FRONT HUBS ONLY ON FRONT WHEEL DRIVE (FWD) VEHICLES AND TO FRONT AND REAR HUBS ON ALL WHEEL DRIVE (AWD) VEHICLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1656 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 1657 Measure hub wheel pilot diameter (refer to Figure 4). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels Wheels: All Technical Service Bulletins Recall - Stamped Steel Road Wheels No. 603 January, 1994 To: All Dodge and Chrysler-Plymouth Dealers Subject: Safety Recall # 603 -- Stamped Steel Road Wheels Models: 1994 Model Year Dodge Grand Caravan, Plymouth Grand Voyager and Chrysler Town and Country Vehicles Built on September 23 and 24, 1993 and Equipped with 15" Stamped Steel Wheels and/or a 15" Full Size Stamped Steel Spare. The nut seat of the stamped steel road wheel may be misformed and result in the loss of lug nut torque retention. To correct the condition, all wheels must be inspected for an "M1" manufacturing plant code and all suspect wheels must be replaced. Less than 100 vehicles are involved in this recall. IMPORTANT: Some of the involved vehicles may be in dealer inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by Certified Mail. Important: Dealer notification by Certified Mail is required by federal law for all safety recalls. Responsible dealership personnel should be instructed to sign for this Certified Mail without hesitation as it concerns urgent safety recall information. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. All dealers: Each Dodge and Chrysler-Plymouth dealer will receive a copy of this dealer recall notification letter by Compak mail. DIAL System Function 70 All involved vehicles will be entered to DIAL System Function 70 at the time of recall implementation for dealer inquiry by VIN as needed. Parts Important: Due to the small number of involved vehicles and the unknown number of wheels required for each vehicle, no parts will be distributed initially to dealers. Dealers are requested to order parts only to support scheduled repairs. Wheel Packages, Recall PN C3905750, may be ordered at dealer cost to support customer demand. Owners were requested to inspect their vehicle to determine the number of replacement wheels required. Dealers should inquire if the owner performed the inspection and order the required parts when scheduling the service appointment. Each parts package contains the components (see illustration). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 1662 Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to inspect wheels for the suspect manufacturing plant code and/or schedule appointments for the service with their dealers at the earliest possible date. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure A. Inspect Wheel Manufacturing Plant Code: NOTE: Vehicle may have one, four or five wheels to be inspected. A1. FOR VEHICLES EQUIPPED WITH 15" STAMPED STEEL WHEELS (Sales Code WCF): a. Remove all wheel covers. b. Inspect wheel manufacturing plant code located above valve stem (Figure 1). NOTE: Manufacturing plant code may be covered by a green sticker. Remove and discard sticker as necessary. A2. FOR VEHICLES EQUIPPED WITH 15" FULL SIZE STAMPED STEEL SPARE (Sales Code -TBB): a. Gain access to spare. b. Inspect wheel manufacturing plant code located above valve stem (Figure 1). NOTE: Manufacturing plant code may be covered by a green sticker. Remove and discard sticker as necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 1663 A3. If any of the wheels inspected contain a Manufacturing Plant Code of M1, replace the affected wheel as instructed in Section B. If none of the wheels have the M1 plant code, reinstall wheel covers and/or secure spare, no further action is required. NOTE: Replace only those wheels having the M1 plant code. B. Replace Wheel: B1. Remove all wheels with suspect M1 plant code. Discard lug nuts. B2. Remove tire(s) from wheel(s). Set wheel(s) aside for return to Warranty Material Return Center. B3. Install supplied valve stem(s). B4. Mount and balance tire(s) on supplied wheel(s). B5. Install wheel and tire assembly on vehicle using supplied lug nuts. Tighten lug nuts to 95 ft.lbs. (130 N-m) torque. B6. Reinstall wheel cover(s) and/or secure spare. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances (see illustration). Add the cost of any recall parts packages used plus applicable dealer allowance to your claim. Parts Return Removed wheels must be returned to the Warranty Material Return Center. Note: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation 429-10-04 P.O. Box 1919 Detroit, Michigan 48231-1919 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 1664 SAFETY RECALL -- Stamped Steel Road Wheels Dear Chrysler Corporation Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1994 model Dodge Grand Caravan, Chrysler Town & Country and Plymouth Grand Voyager vehicles. The lug nuts attaching the stamped steel road wheels may loosen and result in a wheel becoming loose. This could result in an accident without prior warning. Your vehicle, identified on the enclosed form, is affected. For this reason we ask that you arrange for service to correct the condition without delay. The service and required parts as described in this letter will be provided free of charge. The stamped steel road wheel lug nut seats may have been misformed with an incorrect taper, which can result in loosening of the lug nuts. These wheels were used on vehicles equipped with 15" wheels with full wheel covers and also for 15" full size spare tires. You may inspect for suspect wheels yourself. Please refer to the instructions on the reverse side of this letter for details. If no suspect wheels are found, no further action is necessary. Please mark "INSPECTED -- OK" on the pre-addressed Vehicle Disposition Form portion of the enclosed owner notification form and put it in the mail. No postage is required. If you prefer not to do the inspection yourself, your dealer will do the inspection for you. To correct the condition, your dealer will inspect the manufacturing plant code of all steel wheels and replace any suspect wheels. The inspection will take less than one-half hour to complete. However, additional time may be required depending on how many wheels require replacement and how dealer appointments are scheduled and processed. To obtain this free service: ^ Contact your dealer as soon as possible to schedule an appointment for the service. If you performed the wheel inspection, be sure to inform your dealer of the number of suspect wheels found on your vehicle so the proper quantity of replacement wheels is ordered prior to your service appointment. ^ Take the enclosed Owner Notification Form with you at the time of your appointment and give it to your dealer. The form identifies the vehicle and the service that is required. If you have any problem obtaining the needed repair, please call the Chrysler Customer Center, toll free, at (800) 992-1997. A representative will assist you in getting your vehicle repaired. We regret any inconvenience which this action may cause you. However, we are concerned about your safety. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington D.C. area residents may call 366-0123.) Thank you for your attention to this important matter. STAMPED STEEL WHEEL INSPECTION INSTRUCTIONS 1994 DODGE GRAND CARAVAN, PLYMOUTH GRAND VOYAGER AND CHRYSLER TOWN & COUNTRY FOR VEHICLES EQUIPPED WITH 15" STAMPED STEEL WHEELS: ^ Remove all wheel covers. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 1665 ^ Inspect wheel manufacturing plant code located above valve stem as shown. ^ Reinstall wheel covers. FOR VEHICLES EQUIPPED WITH A 15" STAMPED STEEL WHEEL FULL SIZE SPARE: Gain access to spare following the instructions in your Owner's Manual. Inspect wheel manufacturing plant code located above valve stem as shown. If any of the wheels inspected contain a manufacturing plant code of M1, make an appointment with your dealer to have the suspect wheel(s) replaced. NOTE: Plant code may be covered by a green sticker. Remove and discard sticker as necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments Fig. 3 Wheel bearing assembly 1. Raise and support rear of vehicle. 2. Tighten adjusting nut to specifications, while rotating wheel. 3. Stop wheel and loosen adjusting nut by 1/4 turn. 4. Tighten adjusting nut finger tight. Endplay should be .001-.003 inch. 5. Install castle lock with slots aligned with cotter pin hole. 6. Install cotter pin and grease cap. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front This hub and bearing assembly is being used on certain extended wheelbase Caravan, Voyager and Mini Ram Vans. This unit is serviced as a complete assembly, and is attached to the steering knuckle by four mounting screws that are removed from the rear of the knuckle assembly. Remove 1. Remove cotter pin, nut lock, and spring washer. 2. Loosen hub nut while the vehicle is on the floor with the brakes applied. The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut. 3. Raise vehicle. 4. Remove hub nut, washer, and wheel and tire assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1671 5. Disconnect tie rod end from steering arm with Tool C-3894-A. 6. Remove clamp bolt securing ball joint stud into steering knuckle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1672 7. Remove caliper guide pins and separate caliper assembly from braking disc. SUPPORT CALIPER WITH WIRE HOOK AND NOT BY HYDRAULIC HOSE. Remove braking disc. 8. Separate ball joint stud from knuckle assembly. Pull knuckle assembly out and away from driveshaft. NOTE: Care must be taken not to separate the Inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint, driveshaft must be supported. 9. Remove the four hub and bearing assembly mounting screws from rear of steering knuckle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1673 10. Remove hub and bearing assembly. Replacement of the grease seal is recommended whenever this service is performed. Installation 1. Install new hub and bearing assembly and tighten screws in a criss-cross pattern to 45 ft.lbs. (65 Nm.). CAUTION: Knuckle and bearing mounting surfaces must be smooth and completely free of foreign material or nicks. 2. Position new seal in recess and assemble installer Tool C-4698 tool is provided with a handle and dual purpose drive head for installing seal into knuckle and (head reversed) for installing wear sleeve into C/V joint housing). 3. Assemble tool and install seal. CAUTION: During any service procedures where knuckle and driveshaft are separated, thoroughly clean seal and wear sleeve and relubricate BOTH components. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1674 4. Lubricate the full circumference of the seal (and wear sleeve) with MOPAR Multi-Purpose Lubricant or equivalent. 5. Install driveshaft through hub, then install steering knuckle assembly on lower control arm ball joint stud. 6. Install original (or equivalent) ball joint to knuckle clamp bolt, torque to 95 Nm (70 ft.lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1675 7. Install tie rod end into steering arm, tighten nut to 47 Nm (35 ft.lbs.) torque and install cotter key. 8. Install braking disc. 9. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment on knuckle assembly. Install guide pins and tighten to 25-35 Nm (18-26 ft.lbs.). When installing guide pins, use extreme caution not to cross the threads. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1676 10. Install washer and hub nut after cleaning foreign matter from threads. 11. With brakes applied, tighten nut to 180 ft.lbs. (244 Nm). 12. Install spring washer, nut lock, and new cotter pin. Wrap cotter pin prongs tightly around nut lock. 13. Install wheel and tire assembly. Tighten wheel nuts to 85 ft.lbs. (115 Nm). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1677 Wheel Bearing: Service and Repair Rear REMOVAL AND INSTALLATION 1. Remove the rear tire and wheel assembly. 2. Remove grease cap, cotter pin, nut lock, nut, thrust washer and outer wheel bearing. 3. Carefully slide hub or drum from spindle. Do not drag inner bearing or grease seal over stub axle (thread, bearing, and oil seal may be damaged.) Using an appropriate tool remove the grease seal and inner bearing from the drum or hub. Discard grease seal, a new seal should be used when reinstalling the inner bearing. 4. Thoroughly clean all old grease from the outer and inner bearings, bearing cups and hub cavity. To clean bearings, soak them in an appropriate cleaning solvent. Strike the flat surface of the bearing inner race against a hardwood block several times, to loosen grease. Immerse the bearings in solvent between blows to jar loose and wash old particles of hardened grease from bearings. Repeat this operation until bearings are clean. Bearings can be dried using compressed air but do not spin the bearings. After cleaning, oil the bearings with engine oil. Insert the bearing into its appropriate cup, apply pressure to the bearing while rotating it to test them for pitting and roughness. Replace all worn or defective bearings. If bearing shows signs of pitting or roughness they should be replaced. Bearings must be replaced as a set, both the cup and the bearing need to be replaced at the same time. If bearings are suitable for further use, remove engine oil from bearings using appropriate solvent and dry bearings. Repack the bearings using a Multi-Purpose NLGI. Grade 2 EP Grease such as Mopar® or equivalent, and place them in a clean covered container until ready for installation. If a bearing packer is not available, hand pack grease into all cavities between bearing cage and rollers. 5. If bearings and cups are to be replaced, remove cups from the drum or hub using a brass drift or suitable remover. 6. Replace bearing cups with appropriate installing tool. 7. Install inner bearing in grease coated hub and bearing cup, and install new grease seals using the appropriate seal installer. 8. Coat outer hub cavity and cup with grease. 9. Before installing hub or drum assembly, inspect stub axle and seal surface for burrs or roughness, and smooth out all rough surfaces. 10. Coat the stub axle with Multi-Purpose NLGI, Grade 2 EP grease or equivalent. 11. Carefully slide the hub of drum assembly onto the stub axle. Do not drag seal or inner bearing over the threaded area of the stub axle. 12. Install outer bearing, thrust washer and nut. 13. Tighten the wheel bearing adjusting nut to 27 to 34 Nm (240 to 300 in.lbs.) while rotating hub or drum assembly. This seats the bearings. 14. Back off adjusting nut 1/4 turn (90°) then tighten adjusting nut only finger tight. 15. Position the nut lock over the bearing adjusting nut with one pair of slots in line with the cotter pin hole in the stub axle. Install cotter pin. 16. Install the grease caps and the wheel and tire assemblies. Tighten wheel stud nuts to 115 Nm (85 ft. lbs.) on all models. Reinstall wheel covers if so equipped. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front Wheel Hub: Service and Repair Front This hub and bearing assembly is being used on certain extended wheelbase Caravan, Voyager and Mini Ram Vans. This unit is serviced as a complete assembly, and is attached to the steering knuckle by four mounting screws that are removed from the rear of the knuckle assembly. Remove 1. Remove cotter pin, nut lock, and spring washer. 2. Loosen hub nut while the vehicle is on the floor with the brakes applied. The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut. 3. Raise vehicle. 4. Remove hub nut, washer, and wheel and tire assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 1682 5. Disconnect tie rod end from steering arm with Tool C-3894-A. 6. Remove clamp bolt securing ball joint stud into steering knuckle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 1683 7. Remove caliper guide pins and separate caliper assembly from braking disc. SUPPORT CALIPER WITH WIRE HOOK AND NOT BY HYDRAULIC HOSE. Remove braking disc. 8. Separate ball joint stud from knuckle assembly. Pull knuckle assembly out and away from driveshaft. NOTE: Care must be taken not to separate the Inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint, driveshaft must be supported. 9. Remove the four hub and bearing assembly mounting screws from rear of steering knuckle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 1684 10. Remove hub and bearing assembly. Replacement of the grease seal is recommended whenever this service is performed. Installation 1. Install new hub and bearing assembly and tighten screws in a criss-cross pattern to 45 ft.lbs. (65 Nm.). CAUTION: Knuckle and bearing mounting surfaces must be smooth and completely free of foreign material or nicks. 2. Position new seal in recess and assemble installer Tool C-4698 tool is provided with a handle and dual purpose drive head for installing seal into knuckle and (head reversed) for installing wear sleeve into C/V joint housing). 3. Assemble tool and install seal. CAUTION: During any service procedures where knuckle and driveshaft are separated, thoroughly clean seal and wear sleeve and relubricate BOTH components. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 1685 4. Lubricate the full circumference of the seal (and wear sleeve) with MOPAR Multi-Purpose Lubricant or equivalent. 5. Install driveshaft through hub, then install steering knuckle assembly on lower control arm ball joint stud. 6. Install original (or equivalent) ball joint to knuckle clamp bolt, torque to 95 Nm (70 ft.lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 1686 7. Install tie rod end into steering arm, tighten nut to 47 Nm (35 ft.lbs.) torque and install cotter key. 8. Install braking disc. 9. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment on knuckle assembly. Install guide pins and tighten to 25-35 Nm (18-26 ft.lbs.). When installing guide pins, use extreme caution not to cross the threads. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 1687 10. Install washer and hub nut after cleaning foreign matter from threads. 11. With brakes applied, tighten nut to 180 ft.lbs. (244 Nm). 12. Install spring washer, nut lock, and new cotter pin. Wrap cotter pin prongs tightly around nut lock. 13. Install wheel and tire assembly. Tighten wheel nuts to 85 ft.lbs. (115 Nm). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 1688 Wheel Hub: Service and Repair Rear REMOVAL AND INSTALLATION 1. Remove the rear tire and wheel assembly. 2. Remove grease cap, cotter pin, nut lock, nut, thrust washer and outer wheel bearing. 3. Carefully slide hub or drum from spindle. Do not drag inner bearing or grease seal over stub axle (thread, bearing, and oil seal may be damaged.) Using an appropriate tool remove the grease seal and inner bearing from the drum or hub. Discard grease seal, a new seal should be used when reinstalling the inner bearing. 4. Thoroughly clean all old grease from the outer and inner bearings, bearing cups and hub cavity. To clean bearings, soak them in an appropriate cleaning solvent. Strike the flat surface of the bearing inner race against a hardwood block several times, to loosen grease. Immerse the bearings in solvent between blows to jar loose and wash old particles of hardened grease from bearings. Repeat this operation until bearings are clean. Bearings can be dried using compressed air but do not spin the bearings. After cleaning, oil the bearings with engine oil. Insert the bearing into its appropriate cup, apply pressure to the bearing while rotating it to test them for pitting and roughness. Replace all worn or defective bearings. If bearing shows signs of pitting or roughness they should be replaced. Bearings must be replaced as a set, both the cup and the bearing need to be replaced at the same time. If bearings are suitable for further use, remove engine oil from bearings using appropriate solvent and dry bearings. Repack the bearings using a Multi-Purpose NLGI. Grade 2 EP Grease such as Mopar® or equivalent, and place them in a clean covered container until ready for installation. If a bearing packer is not available, hand pack grease into all cavities between bearing cage and rollers. 5. If bearings and cups are to be replaced, remove cups from the drum or hub using a brass drift or suitable remover. 6. Replace bearing cups with appropriate installing tool. 7. Install inner bearing in grease coated hub and bearing cup, and install new grease seals using the appropriate seal installer. 8. Coat outer hub cavity and cup with grease. 9. Before installing hub or drum assembly, inspect stub axle and seal surface for burrs or roughness, and smooth out all rough surfaces. 10. Coat the stub axle with Multi-Purpose NLGI, Grade 2 EP grease or equivalent. 11. Carefully slide the hub of drum assembly onto the stub axle. Do not drag seal or inner bearing over the threaded area of the stub axle. 12. Install outer bearing, thrust washer and nut. 13. Tighten the wheel bearing adjusting nut to 27 to 34 Nm (240 to 300 in.lbs.) while rotating hub or drum assembly. This seats the bearings. 14. Back off adjusting nut 1/4 turn (90°) then tighten adjusting nut only finger tight. 15. Position the nut lock over the bearing adjusting nut with one pair of slots in line with the cotter pin hole in the stub axle. Install cotter pin. 16. Install the grease caps and the wheel and tire assemblies. Tighten wheel stud nuts to 115 Nm (85 ft. lbs.) on all models. Reinstall wheel covers if so equipped. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls for Wheel Fastener: > NHTSA93V215000 > Dec > 93 > Recall 93V215000: Defective Wheel Lug Nut Seats Wheel Fastener: Recalls Recall 93V215000: Defective Wheel Lug Nut Seats WHEELS WITH MISFORMED LUG NUT SEATS WERE INSTALLED ON THESE VEHICLES. THIS CAUSES REDUCED NUT TO WHEEL CONTACT AREA AND LIMITS THE WHEEL SELF-CENTERING CAPABILITY DURING INSTALLATION. THIS RESULTS IN LOSS OF WHEEL LUG NUT TORQUE RETENTION. LOSS OF LUG NUT TORQUE RETENTION MAY LEAD TO WHEEL LUG FAILURE WHICH MAY CAUSE WHEEL SEPARATION AND AN ACCIDENT. INSPECT THE WHEEL ASSEMBLY PLANT CODE; REPLACE WHEELS KNOWN TO HAVE THE PROBLEM AND INSTALL NEW LUG NUTS. SYSTEM: WHEELS; LUGS; NUTS. VEHICLE DESCRIPTION: VANS WITH 15" STAMPED STEEL ROAD WHEELS OR 15" STAMPED STEEL SPARE WHEEL. NOTE: IF YOU HAVE ANY PROBLEMS OBTAINING THE NEEDED REPAIR, PLEASE CONTACT THE CHRYSLER ZONE SERVICE OFFICE IN YOUR AREA. IT IS LISTED UNDER"SERVICE ASSISTANCE" IN YOUR OWNER'S MANUAL. A ZONE REPRESENTATIVE WILL ARRANGE FOR PROMPT ATTENTION TO YOUR VEHICLE. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTATRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. 1994 CHRYSLER TRUCK TOWN AND COUNTRY 1994 DODGE TRUCK GRAND CARAVAN 1994 PLYMOUTH TRUCK GRAND VOYAGER Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > NHTSA93V215000 > Dec > 93 > Recall 93V215000: Defective Wheel Lug Nut Seats Wheel Fastener: All Technical Service Bulletins Recall 93V215000: Defective Wheel Lug Nut Seats WHEELS WITH MISFORMED LUG NUT SEATS WERE INSTALLED ON THESE VEHICLES. THIS CAUSES REDUCED NUT TO WHEEL CONTACT AREA AND LIMITS THE WHEEL SELF-CENTERING CAPABILITY DURING INSTALLATION. THIS RESULTS IN LOSS OF WHEEL LUG NUT TORQUE RETENTION. LOSS OF LUG NUT TORQUE RETENTION MAY LEAD TO WHEEL LUG FAILURE WHICH MAY CAUSE WHEEL SEPARATION AND AN ACCIDENT. INSPECT THE WHEEL ASSEMBLY PLANT CODE; REPLACE WHEELS KNOWN TO HAVE THE PROBLEM AND INSTALL NEW LUG NUTS. SYSTEM: WHEELS; LUGS; NUTS. VEHICLE DESCRIPTION: VANS WITH 15" STAMPED STEEL ROAD WHEELS OR 15" STAMPED STEEL SPARE WHEEL. NOTE: IF YOU HAVE ANY PROBLEMS OBTAINING THE NEEDED REPAIR, PLEASE CONTACT THE CHRYSLER ZONE SERVICE OFFICE IN YOUR AREA. IT IS LISTED UNDER"SERVICE ASSISTANCE" IN YOUR OWNER'S MANUAL. A ZONE REPRESENTATIVE WILL ARRANGE FOR PROMPT ATTENTION TO YOUR VEHICLE. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTATRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. 1994 CHRYSLER TRUCK TOWN AND COUNTRY 1994 DODGE TRUCK GRAND CARAVAN 1994 PLYMOUTH TRUCK GRAND VOYAGER Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 1702 Wheel Fastener: Specifications Fig 6 Wheel Stud Tightening Sequence When tightening wheel stud nuts, a criss-cross tightening sequence as shown should be followed. Tighten all stud nuts to one-half specified torque. Repeat, fully tightening to specified torque. Wheel stud lug nut torque 129 Nm (95 ft lb) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Locations Fig. 1 Caravan, Town & Country & Voyager Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Cylinder Compression Pressure 100 psi NOTE: No more than 25% variance between cylinders. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1711 Compression Check: Service Precautions COMPRESSION TESTING When performing a compression test, remove the fuel pump relay fuse and disconnect power to the ignition. This will stop fuel flow to the injectors and prevent engine from starting. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1712 Compression Check: Testing and Inspection PROCEDURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire (Conventional Ignition System). For Direct Ignition System (DIS) disconnect the coil connector. 5 . Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adaptor into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is reached on gage. Record this pressure as #1 cylinder pressure. 7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 9. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. 11. Clean or replace spark plugs as necessary and adjust gap. Tighten to specifications. 12. Test resistance of spark plug cables. Perform secondary circuit inspection. 13. Test coil output voltage, primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at idle and different RPM ranges. 15. The air filter elements should be replaced as specified. 16. Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt drives. 18. Road test vehicle as a final test. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications DIAMETER: No. 1 .............................................................................................................................................................. 50.825 - 50.800 mm (2.0009 - 1.9999 inch) No. 2 .............................................................................................................................................................. 50.419 - 50.393 mm (1.9849 - 1.9839 inch) No. 3 .............................................................................................................................................................. 50.038 - 50.013 mm (1.9699 - 1.9690 inch) No. 4 .............................................................................................................................................................. 49.632 - 49.606 mm (1.9540 - 1.9529 inch) Oil Clearance ......................................................................................................................................................... 0.0254 - 0.0762 mm (0.001 - 0.003 inch) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Page 1717 Camshaft Bearing: Service and Repair REMOVAL 1. With engine removed from vehicle and completely disassembled, drive out rear cam bearing core hole plug. 2. Install proper size adapters and horseshoe washers part of Tool C-3132-A, or equivalent at back of each bearing shell to be removed and drive out bearing shells. INSTALLATION 1. Install new camshaft bearings with Tool C-3132-A, or equivalent by sliding the new camshaft bearing shell over proper adapter. 2. Position rear bearing in the tool. Install horse-shoe lock and by reversing removal procedure, carefully drive bearing shell into place. 3. Install remaining bearings in the same manner. Bearings must be carefully aligned to bring oil holes into full register with oil passages from the main bearing. Number two bearing must index with the oil passage to the left cylinder head and Number three bearing must index with the oil passage to the right cylinder head. If the camshaft bearing shell oil holes are not in exact alignment, remove and reinstall them correctly. Install a new core hole plug at the rear of camshaft. Be sure this plug does not leak. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Page 1718 Camshaft Bearing Remover and Installer C-3132-A Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt ....................................................................................................................... .................................................... 54 Nm (40 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Thrust Plate > Component Information > Specifications Camshaft Thrust Plate: Specifications Mounting Bolts ..................................................................................................................................... ............................................... 12 Nm (105 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications CAMSHAFT Drive .................................................................................................................................................... .................................................................... Chain Bearings ............................................................... ............................................................................................................................ Steel Backed Babbitt Number .................................................................................................................................... ....................................................................................... 4 Diametral Clearance ................................................................................................................................................ 0.025 0.101 mm (0.001 - 0.004 in.) Maximum Allowable Before Reconditioning ............................................................................................................................ 0.127 mm (0.005 in.) Thrust Taken By .................................................................................................................................. .......................................................... Thrust Plate End Play ............................................................... ................................................................................................... 0.127 - 0.304 mm (0.005 - 0.012 in.) Maximum Allowable ............................................................................................................................. .......................................... 0.304 mm (0.012 in.) CAMSHAFT JOURNALS Diameter No. 1 ......................................................................................................................................................... 50.724 - 50.775 mm (1.9970 - 1.9990 in.) No. 2 ......................................................................................................................................................... 50.317 - 50.368 mm (1.9809 - 1.9829 in.) No. 3 ......................................................................................................................................................... 49.936 - 49.987 mm (1.9659 - 1.9679 in.) No. 4 ......................................................................................................................................................... 49.530 - 49.581 mm (1.9499 - 1.9520 in.) CAMSHAFT BEARINGS Diameter No. 1 ......................................................................................................................................................... 50.825 - 50.800 mm (2.0009 - 1.9999 in.) No. 2 ......................................................................................................................................................... 50.419 - 50.393 mm (1.9849 - 1.9839 in.) No. 3 ......................................................................................................................................................... 50.038 - 50.013 mm (1.9699 - 1.9690 in.) No. 4 ......................................................................................................................................................... 49.632 - 49.606 mm (1.9540 - 1.9529 in.) Oil Clearance ......................................................................................................................................................... .0254 - .0762 mm (.001 - 003 in.) VALVE TIMING Intake Opens (BTC) ............................................................................................................................. ......................................................................... 2° Intake Closes (ABC) ............................................. ....................................................................................................................................................... 58° Exhaust Opens (BBC) ......................................................................................................................... ........................................................................ 48° Exhaust Closes (ATC) ......................................... ........................................................................................................................................................ 12° Valve Overlap ............................................................................................................................... ............................................................................... 14° Intake Valve Duration .................................... ........................................................................................................................................................... 240° Exhaust Valve Duration .............................................................................................................. ............................................................................... 240° TIMING CHAIN Number of Links .................................................................................................................................. ......................................................................... 64 Pitch ...................................................................... .............................................................................................................................................. 0.375 in. Width ................................................................................................................................................... ............................................................... 0.750 in. TAPPETS Type ..................................................................................................................................................... ................................................... Roller Hydraulic Body Diameter .................................................................................................................................................... 22.95 - 22.96 mm (0.9035 - 0.9040 in.) Clearance to Block .................................................................................................................................................. 0.02 0.06 mm (0.0007 - 0.0024 in.) Service Tappets Available ................................................................... ....................................................................................................................... Std. .............................................................................................................................................................. ...................................... 0.025 mm (0.001 in.) .................................................................................... .................................................................................................................. 0.20 mm (0.008 in.) .......... .............................................................................................................................................................. ............................ 0.762 mm (0.030 in.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1728 Camshaft: Description and Operation The nodular iron camshaft is mounted in four steel backed Babbitt bearings. A thrust plate located in front of the first bearing, and bolted to the block, controls end play. Silent timing chain drives the camshaft. This chain is enclosed by a cast aluminum cover which also carries a front crankshaft seal, provides front oil pan closure and water pump mounting. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement Camshaft: Service and Repair Camshaft Replacement 1. Remove intake manifold as described under Intake Manifold Replacement. 2. Remove timing case cover and chain as described under Timing Chain Service. 3. Remove rocker arm and shaft assemblies and cylinder heads as described under Cylinder Head Replacement. 4. Remove camshaft thrust plate. 5. Install a long bolt into camshaft to facilitate removal of camshaft, then remove camshaft. 6. Reverse procedure to install, noting following: a. Tighten thrust plate to specifications. b. Refer to Timing Chain Service for installation of timing chain and sprockets. c. If new camshaft is installed, new tappets must be used. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 1731 Camshaft: Service and Repair Removal and Installation Replacement With Engine Out of Vehicle REMOVAL Remove intake manifold, cylinder head covers, cylinder heads, timing chain case cover and timing chain. 1. Remove rocker arm and shaft assemblies. 2. Remove push rods and tappets; identify so each part will be replaced in its original location. 3. Remove camshaft thrust plate. 4. Install a long bolt into front of camshaft to facilitate removal of the camshaft; remove camshaft, being careful not to damage cam bearings with the cam lobes. INSTALLATION 1. Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 2 inches of its final position in cylinder block. NOTE: Whenever an engine has been rebuilt or a new camshaft or tappets have been installed, add one pint of Mopar (R) Engine Oil Supplement or equivalent to engine oil to aid in break-in. The oil mixture should be left in engine for a minimum of 805 km (500 miles) and drained at the next normal oil change. 2. Install camshaft thrust plate with two screws as shown. Tighten to 12 Nm (105 inch lbs.) torque. 3. Rotate crankshaft so the timing arrow is at the 12 o'clock position. 4. Place timing chain around camshaft sprocket and place the timing mark to the 6 o'clock position. 5. Align the dark colored links with the dot on the camshaft sprocket, place timing chain around crankshaft sprocket with the dark colored link lined up with the dot on the sprocket and install camshaft sprocket into position. 6. Using straight edge to check alignment of timing marks. 7. Install the camshaft bolt. Tighten bolt to 54 Nm (40 ft. lbs.). 8. Rotate crankshaft 2 revolutions. Timing marks should line up. If timing marks do not line up, remove cam sprocket and realign. 9. Measure camshaft end play. End Play should measure 0.0127 to 0.304 mm (0.005 to 0.012 inch) 0.310 mm (0.012 inch Max.). If not within limits install a new thrust plate. 10. Each tappet reused must be installed in the same position from which it was removed. When camshaft is replaced, all of the tappets must be replaced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Hydraulic Lash Adjuster <--> [Lifter / Lash Adjuster, Valve] > Component Information > Specifications Hydraulic Lash Adjuster: Specifications Type ..................................................................................................................................................... ........................................................ Roller Hydraulic Body Diameter ...................................................................................................................................................... 22.95 - 22.96 mm (0.9035 - 0.9040 inch) Clearance To Block ................................................................................................................................................... 0.02 0.06 mm (0.0007 - 0.0024 inch) Retainer Yoke Screw ........................................................................ ................................................................................................... 12 Nm (105 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Hydraulic Lash Adjuster <--> [Lifter / Lash Adjuster, Valve] > Component Information > Specifications > Page 1735 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Hydraulic Lash Adjuster <--> [Lifter / Lash Adjuster, Valve] > Component Information > Specifications > Page 1736 Hydraulic Lash Adjuster: Testing and Inspection GENERAL INFORMATION The valve train includes roller tappet assemblies, aligning yokes and yoke retainer. Roller tappet alignment is maintained by machined flats on tappet body being fitted in pairs into six aligning yokes. The yokes are secured by an alignment yoke retainer. PRELIMINARY STEP TO CHECKING THE HYDRAULIC TAPPETS Before disassembling any part of the engine to correct tappet noise, read the oil pressure at the gauge. Install a reliable gauge at pressure sending unit if vehicle has no oil pressure gauge and check the of level in the oil pan. The pressure should be between 30 and 80 psi (206.8 to 651.6 kPa) at 2000 rpm. The oil level in the pan should never be above the MAX mark on dipstick, or below the MIN mark. Either of these two conditions could be responsible for noisy tappets. Oil Level Check: stop engine after reaching normal operating temperature. Allow 5 minutes to stabilize oil level, check dipstick. Oil Level Too High If oil level is above the MAX mark on dip stick, it is possible for the connecting rods to dip into the oil while engine is running and create foam. Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to become soft and allow valves to seat noisily. Oil Level Too Low Low oil level may allow pump to take in air which when fed to the tappets, causes them to become soft and allows valves to seat noisily. Any leaks on intake side of pump through which air can be drawn will create the same tappet action. Check the lubrication system from the intake strainer to the pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may be intermittent or constant, and usually more than one tappet will be noisy. When oil level and leaks have been corrected, engine should be operated at fast idle to allow all of the air inside of the tappets to be bled out. VALVE TRAIN NOISE DIAGNOSIS To determine if a clicking noise coming from the engine compartment is caused by a tappet. Increase the engine speed above idle speed to check if the clicking frequency rises with engine speed. If it does not, the clicking noise is not coming from the engine. If it is determined that the clicking noise is coming from the engine, alternately increase and decrease the engine speed quickly by opening and closing the throttle. If the clicking noise changes significantly in loudness from when the engine speed is increasing te engine speed decreasing, the noise is probably net coming from the tappet. Valve tappet noise ranges from light noise to a heavy click. A light noise is usually caused by excessive leak-down around the unit plunger which will necessitate replacing the tappet, or by the plunger partially sticking in the tappet body cylinder. A heavy click is caused either by a tappet check valve nOt seating, or by foreign particles becoming wedged between the plunger and the tappet body causing the plunger to stick in the down position. This heavy click will be accompanied by excessive clearance between the valve stem and rocker arm as valve closes. In either case, tappet assembly should be removed for inspection and clesning. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Hydraulic Lash Adjuster <--> [Lifter / Lash Adjuster, Valve] > Component Information > Service and Repair > Removal and Installation Hydraulic Lash Adjuster: Service and Repair Removal and Installation REMOVAL 1. Cylinder Head must be removed to gain access to tappets for service. 2. Remove yoke retainer and aligning yokes. 3. Use Tool C-4129, or equivalent to remove tappets from their bores. If all tappets are to be removed, identify tappets to insure installation in original location. NOTE: If the tappet or bore in cylinder block is scored, scuffed, or shows signs of sticking, ream the bore to next oversize and replace with oversize tappet. CAUTION: The plunger and tappet bodies are not interchangeable. The plunger and valve must always be fitted to the original body. It is advisable to work on one tappet at a time to avoid mixing of parts. Mixed parts are not compatible. Do not disassemble a tappet on a dirty work bench. INSTALLATION 1. Lubricate tappets. 2. Install tappets in their original positions. 3. With roller tappets, install aligning yokes. 4. Install yoke retainer and torque screws to 12 Nm (105 inch lbs.). 5. Install cylinder heads. 6. Start and operate engine. Warm up to normal operating temperature. CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become quiet. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Hydraulic Lash Adjuster <--> [Lifter / Lash Adjuster, Valve] > Component Information > Service and Repair > Removal and Installation > Page 1739 Hydraulic Lash Adjuster: Service and Repair Disassembly and Assembly DISASSEMBLY 1. Pry out plunger retainer spring clip. 2. Clean varnish deposits from inside of tappet body above plunger cap. 3. Invert tappet body and remove plunger cap, plunger, flat or ball check valve, check valve spring, check valve retainer and plunger spring. Check valve could be flat or ball. ASSEMBLY 1. Clean all tappet parts in a solvent that will remove all varnish and carbon. 2. Replace tappets that are unfit for further service with new assemblies. 3. If plunger shows signs of scoring or wear, valve is pitted, or valve seat on end of plunger indicates any condition that would prevent valve from seating, install a new tappet assembly. 4. Assemble tappets. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Rocker Arm and Shaft Rocker Arm Assembly: Specifications Rocker Arm and Shaft Bracket Bolt ......................................................................................................................................... ............................................... 28 Nm (250 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Rocker Arm and Shaft > Page 1744 Rocker Arm Assembly: Specifications Rocker Arm Bolts 250 in.lb Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1745 Rocker Arm Assembly: Description and Operation Rocker arms are installed on a rocker arm shaft attached to the cylinder head with four bolts and retainers. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1746 Rocker Arm Assembly: Service and Repair REMOVAL 1. Remove upper intake manifold assembly. Refer to Intake Manifold. 2. Disconnect spark plug wires by pulling on the boot straight out in line with plug. 3. Disconnect closed ventilation system. 4. Remove cylinder head cover and gasket. 5. Remove four rocker shaft bolts and retainers. 6. Remove rocker arms and shaft assembly. 7. If rocker arm assemblies are disassembled for cleaning or replacement, re-assemble rocker arms in their original position. INSTALLATION 1. Install rocker arm and shaft assemblies with the stamped steel retainers in the four positions, tighten to 28 Nm (250 in. lbs.). CAUTION: The rocker arm shaft should be torqued down slowly, starting with the center bolts. Allow 20 minutes tappet bleed down time after installation of the rocker shafts before engine operation. 2. Clean cylinder head cover gasket surface. Inspect cover for distortion and straighten if necessary. 3. Clean head rail if necessary. Install a new gasket and tighten cylinder head cover fasteners to 12 Nm (105 in. lbs.). 4. Install closed crankcase ventilation system. 5. Install spark plug wires. 6. Install upper intake manifold assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications CONNECTING RODS Side Clearance ........................................................................................................................................................ 0.127 - 0.381 mm (0.005 - 0.015 in.) CONNECTING ROD BEARINGS Type ..................................................................................................................................................... .................................. Aluminum Lead (Bi-Metal) Clearance Desired ............................................................................................................................................... 0.019 0.076 mm (0.00075 - 0.003 in.) Maximum Allowable (wear limit) ................................................................................................................................................... 0.102 mm (0.004 in.) Bearings for Service .................................................................................................... ................................................................................................ Std. .............................................................................................................................................................. ...................................... 0.025 mm (0.001 in.) .................................................................................... ................................................................................................................ 0.051 mm (0.002 in.) .......... .............................................................................................................................................................. ............................ 0.076 mm (0.003 in.) .............................................................................................. ...................................................................................................... 0.254 mm (0.010 in.) .................... .............................................................................................................................................................. .................. 0.305 mm (0.012 in.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Fitting Connecting Rod Bearings Connecting Rod Bearing: Service and Repair Fitting Connecting Rod Bearings GENERAL INFORMATION Fit all rods on one bank until complete. The bearing caps are not interchangeable and should be marked at removal to insure correct assembly. The bearing shells must be installed with the tangs inserted into the machined grooves in the rods and caps. Install cap with the tangs on the same side as the rod. SIZES Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 inch). Bearings are available in 0.025 mm (0.001 inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm (0.010 inch) and 0.305 mm (0.012 inch) undersize. Install the bearings in pairs. Do not use a new bearing half with an old bearing half. Do not file the rods or bearing caps. PROCEDURE 1. Measure Main Bearing Clearance and Connecting Rod Bearing Clearance. NOTE: The rod bearing bolts should be examined before reuse. If the threads are necked down the bolts should be replaced. Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt should be replaced. 2. Before installing the nuts the threads should be oiled with engine oil. 3. Install nuts finger tight on each bolt then alternately torque each nut to assemble the cap properly. 4. Tighten the nuts to 54 Nm PLUS 1/4 turn (40 ft. lbs. PLUS 1/4 turn). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Fitting Connecting Rod Bearings > Page 1753 5. Using a feeler gauge, check connecting rod side clearance. Refer to specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Fitting Connecting Rod Bearings > Page 1754 Connecting Rod Bearing: Service and Repair Connecting Rod Bearing Clearance Engine connecting rod bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage: 1. Rotate the crankshaft until the connecting rod to be checked is at the bottom of its stroke. 2. Remove oil film from surface to be checked. Plastigage is soluble in oil. 3. Place a piece of Plastigage across the entire width of the bearing shell in the bearing cap approximately 6.35 mm (1/4 inch) off center and away from the oil hole. In addition, suspect areas can be checked by placing plastigage in the suspect area. 4. Before assembling the rod cap with Plastigage in place, the crankshaft must be rotated until the connecting being checked starts moving toward the top of the engine. Only then should the cap be assembled and torqued to specifications. Do not rotate the crankshaft while assembling the cap or the Plastigage may be smeared, giving inaccurate results. 5. Remove the bearing cap and compare the width of the flattened Plastigage with the scale provided on the package. Locate the band closest to the same width. This band indicates the amount of oil clearance. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Refer to Engine Specifications. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Technical Service Bulletins > Engine - Piston Knock at Idle Connecting Rod: Technical Service Bulletins Engine - Piston Knock at Idle NO: 09-03-94 GROUP: Engine DATE: Apr. 1, 1994 SUBJECT: Engine Idle Piston Noise MODELS: 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1994 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1994 (LH) Concorde/intrepid/Vision NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 3.3L AND 3.8L ENGINE SYMPTOM/CONDITION: Cold start up piston knocking noise at idle that diminishes 3 to 5 minutes after start up. The condition is more prominent in low ambient temperatures and after the vehicle has set overnight. Similar symptoms are described in Technical Service Bulletin 09-21-93 dated Dec. 31, 1993, "Carbon Buildup on Top of Piston". Refer to this Bulletin for additional details. DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, and carbon buildup on the top of the piston is not evident, proceed with the following repair. PARTS REQUIRED: AR 4621978 Piston & Connecting Rod Assy. (use w/3.3L engine) AR 4621981 Piston & Connecting Rod Assy. (use w/3.8L engine) REPAIR PROCEDURE: This repair involves installing a new coated piston and connecting rod assembly. 1. Following the procedure outlined in the appropriate Service Manual, remove the engine piston and connecting rods. 2. Install the new coated piston and connecting rod assembly as outlined in the Service Manual. NOTE: HONING OF THE CYLINDER BORES IS NOT RECOMMENDED. DISCUSSION: The new pistons have a coating bonded only to the piston skirt that is black in appearance. This new coating replaces the previously used tin coating. Items of special interest include: 1. The new coated pistons are available in one size only and are serviced with the piston pin and connecting rod as an assembly. 2. The new coated piston connecting rod assembly can be used to service all models listed and can be replaced one at a time (complete engine sets are not required). 3. Tin coated pistons should not be used as replacements for the coated pistons. 4. The coating material is applied after the final piston machining process. Therefore, the step for measuring the outside diameter of the piston to determine size or piston to bore clearance is not required. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Technical Service Bulletins > Engine - Piston Knock at Idle > Page 1759 5. Measuring the inside diameter of the cylinder bore with a Bore Gauge is still required. Dial Cylinder Bore Indicator, Tool C-119 available from Miller Special Tools, is recommended. Follow the procedure outlined in the Service Manual. If the cylinder bore measures larger than 3.664 inches (93.059 mm) for the 3.3L Engine, or 3.782 inches (96.059 mm) for the 3.8L Engine, the cylinder block will require replacement. 6. Piston installation into the cylinder bore may require slightly more pressure than that required for non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit with the cylinder bore. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: 1990 - 1994 AC, AS, AY (W/3.3L or 3.8L Engine) Piston and Connecting Rod Replace Labor Operation No. 09-70-01-91 One - Front Bank 4.2 Hrs. 09-70-01-92 One - Rear Bank 4.5 Hrs. 09-70-01-93 One - Each Bank 6.0 Hrs. 09-70-01-94 Each Additional 0.5 Hrs. 09-70-01-63 A/C Equipped 0.2 Hrs. 09-70-01-64 Power Steering Equipped (AS Only) 0.2 Hrs. 1993 - 1994 LH (w/3.3L or 3.8L Engine) Piston and Connecting Rod Replace Labor Operation No. 09-70-01-95 One - Left Bank 4.1 Hrs. 09-70-01-96 One - Right Bank 3.7 Hrs. 09-70-01-97 One - Each Bank 5.2 Hrs. 09-70-01-98 Each Additional 0.5 Hrs. 09-70-01-63 A/C Equipped 0.3 Hrs. FAILURE CODE: 58 - Noisy Cold Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Specifications Connecting Rod: Specifications Connecting Rod Specifications CONNECTING RODS Side Clearance ........................................................................................................................................................ 0.127 - 0.381 mm (0.005 - 0.015 in.) CONNECTING ROD BEARINGS Type ..................................................................................................................................................... .................................. Aluminum Lead (Bi-Metal) Clearance Desired ............................................................................................................................................... 0.019 0.076 mm (0.00075 - 0.003 in.) Maximum Allowable (wear limit) ................................................................................................................................................... 0.102 mm (0.004 in.) Bearings for Service .................................................................................................... ................................................................................................ Std. .............................................................................................................................................................. ...................................... 0.025 mm (0.001 in.) .................................................................................... ................................................................................................................ 0.051 mm (0.002 in.) .......... .............................................................................................................................................................. ............................ 0.076 mm (0.003 in.) .............................................................................................. ...................................................................................................... 0.254 mm (0.010 in.) .................... .............................................................................................................................................................. .................. 0.305 mm (0.012 in.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Removal and Installation Connecting Rod: Service and Repair Removal and Installation NOTE: Heads and Oil Pan have to be removed first. REMOVAL 1. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine; rotate crankshaft so that each connecting rod is centered in cylinder bore. 2. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them if necessary. 3. Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts. Push each piston and rod assembly out of cylinder bore. NOTE: Be careful not to nick crankshaft journals. 4. After removal, install bearing cap on the mating rod. INSTALLATION 1. Before installing pistons and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Removal and Installation > Page 1764 with oil ring rail gap. 2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown. 3. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston and tighten with the special wrench. Be sure position of rings does not change during this operation. 4. Install connecting rod bolt protectors on rod bolts. 5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal. 6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. 7. The notch or groove on top of piston must be pointing toward front of engine. 8. Install rod caps. Install nuts on cleaned and oiled rod bolts and tighten nuts to 54 Nm (40 ft. lb.) Plus 1/4 turn. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Removal and Installation > Page 1765 Connecting Rod: Service and Repair Disassembly and Assembly Fig. 22 Piston Measurements Fig. 23 Piston Ring Installation Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Removal and Installation > Page 1766 Fig. 24 Piston Ring Installation Fig. 25 Ring End Gap Orientation When installing piston and rod assemblies notch in piston top must point toward front of engine. Refer to Fig. 22 through 25 for piston measurements and ring installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Sprocket <--> [Crankshaft Gear/Sprocket] > Component Information > Description and Operation Crankshaft Sprocket: Description and Operation ACCESS PLUG An Access plug is located in the right inner fender shield. Remove the plug and insert the proper size socket, extension and ratchet, when crankshaft rotation is necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications CRANKSHAFT Type ..................................................................................................................................................... ................................................. Cast Nodular Iron Bearings ............................................................... ................................................................................................................ Aluminum Lead (Bi - Metal) Thrust Taken By .................................................................................................................................. .............................................. No. 2 Main Bearing End Play ............................................................... ................................................................................................... 0.076 - 0.228 mm (0.003 - 0.009 in.) Maximum Allowable (wear limit) ................................................................................................................................................... 0.381 mm (0.015 in.) Diametral Clearance Desired ................................................................................................................................ 0.018 - 0.076 mm (0.0007 - 0.003 in.) Maximum Diametral Clearance (wear limit) ................................................................................................................................... 0.102 mm (0.004 in.) MAIN BEARING JOURNALS Diameter .............................................................................................................................................. ................................................. 64 mm (2.519 in.) Maximum Out-of-Round and/or Taper ............................................................................................................................................ 0.025 mm (0.001 in.) Bearings for Service ........................................................................................................... ......................................................................................... Std. .............................................................................................................................................................. ...................................... 0.025 mm (0.001 in.) .................................................................................... ................................................................................................................ 0.051 mm (0.002 in.) .......... .............................................................................................................................................................. ............................ 0.076 mm (0.003 in.) .............................................................................................. ...................................................................................................... 0.254 mm (0.010 in.) .................... .............................................................................................................................................................. .................. 0.305 mm (0.012 in.) CONNECTING ROD JOURNALS Diameter .............................................................................................................................................. ................................................. 58 mm (2.283 in.) Maximum Out-of-Round and/or Taper ............................................................................................................................................ 0.025 mm (0.001 in.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Removal and Installation Crankshaft Main Bearing: Service and Repair Removal and Installation REMOVAL 1. Remove oil pan and identify bearing caps before removal. 2. Remove bearing caps one at a time. Remove upper half of bearing by inserting Special Main Bearing Tool C-3059 into the oil hole of crankshaft. 3. Slowly rotate crankshaft clockwise, forcing out upper half of bearing shell. NOTE: Only one main bearing should be selectively fitted while all other main bearing caps are properly tightened. INSTALLATION When installing a new upper bearing shell, slightly chamfer the sharp edges from the plain side. 1. Start bearing in place, and insert Main Bearing Tool C-3059 into oil hole of crankshaft. 2. Slowly rotate crankshaft counterclockwise sliding the bearing into position. Remove Special Main Bearing Tool C-3059. 3. Install each main cap and tighten bolts finger tight. 4. Tighten number 1, 3 and 4 main cap bolts to 41 Nm plus a 1/4 Turn (30 ft. lbs.) plus a 1/4 Turn. 5. Rotate the crankshaft until number 6 piston is at Top Dead Center (TDC). 6. To ensure correct thrust bearing alignment the following procedure must be done: a. Move crankshaft all the way to the rear of its travel. b. Then, move crankshaft all the way to the front of its travel. c. Wedge a appropriate tool between. the rear of the cylinder block and rear crankshaft counterweight. This will hold the crankshaft in it's most forward position. d. Tighten the #2 Thrust Bearing cap bolts to 41 Nm plus a 1/4 Turn (30 ft. lbs.) plus a 1/4 Turn. Remove the holding tool. NOTE: Whenever an engine has been rebuilt, add one pint of Mopar(R) Engine Oil-Supplement or equivalent to engine oil to aid in break in. The oil mixture should be left in engine for a minimum of 805 km (500 miles) and drained at the next normal oil change. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Removal and Installation > Page 1775 Crankshaft Main Bearing: Service and Repair Inspection Main Journal Inspection MAIN BEARINGS Bearing caps are not interchangeable and should be marked at removal to insure correct assembly. Upper and lower bearing halves are NOT interchangeable. Lower main bearing halves of 1, 3 and 4 are interchangeable. Upper main bearing halves of 1, 3 and 4 are interchangeable. CRANKSHAFT MAIN JOURNALS The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 inch). Journal grinding should not exceed 0.305 mm (0.012 inch) under the standard journal diameter. Do NOT grind thrust faces of Number 2 main bearing. Do NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all passages. CAUTION: With the nodular cast iron crankshafts used is important that the final paper or cloth polish after any journal regrind be in the same direction as normal rotation in the engine. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Removal and Installation > Page 1776 Upper and lower Number 2 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine. All bearing cap bolts removed during service procedures are to be cleaned and oiled before installation. Bearing shells are available in standard and the following undersizes: 0.025 mm (0.001 inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm (0.010 inch), and 0.305 mm (0.012 inch). Never install an undersize bearing that will reduce clearance below specification. Measuring Main Bearing Clearance PLASTIGAGE METHOD Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage: NOTE: The total clearance of the main bearings can only be determined by removing the weight of the crankshaft. This can be accomplished by either of two methods: Preferred Method Shimming the bearings adjacent to the bearing to be checked in order to remove the clearance between upper bearing shell and the crankshaft. This can be accomplished by placing a minimum of 0.254 mm (0.010 inch) shim (e.g. cardboard, match-book cover, etc.) between the bearing shell and the bearing cap on the adjacent bearings and tightening bolts to 14 20 Nm (10 - 15 ft. lbs.). The number of main bearing will vary from engine to engine. ^ When checking #1 main bearing shim # 2 main bearing. ^ When checking #2 main bearing shim #1 & #3 main bearing. ^ When checking #3 main bearing shim #2 & #4 main bearing. ^ When checking #4 main bearing shim #3 main bearing. CAUTION: Remove all shims before reassembling engine. Alternative Method The weight of the crankshaft can be supported by a jack under the counterweight adjacent to the bearing being checked. PLASTIGAGE PROCEDURE 1. Remove oil film from surface to be checked. Plastigage is soluble in oil. 2. Place a piece of Plastigage across the entire width of the bearing shell in the cap approximately 6.35 mm (1/4 inch) off center and away from the oil holes. (In addition, suspected areas can be checked by placing the Plastigage in the suspected area). Torque the bearing cap bolts of the bearing being checked to the proper specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Removal and Installation > Page 1777 3. Remove the bearing cap and compare the width of the flattened Plastigage with the metric scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance in thousandths of a millimeter. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Page 1778 Crankshaft Main Bearing Remover and Installer C-3059 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Rebuild Specifications Crankshaft: Specifications Rebuild Specifications CRANKSHAFT Type ..................................................................................................................................................... ................................................. Cast Nodular Iron Bearings ............................................................... ................................................................................................................ Aluminum Lead (Bi - Metal) Thrust Taken By .................................................................................................................................. .............................................. No. 2 Main Bearing End Play ............................................................... ................................................................................................... 0.076 - 0.228 mm (0.003 - 0.009 in.) Maximum Allowable (wear limit) ................................................................................................................................................... 0.381 mm (0.015 in.) Diametral Clearance Desired ................................................................................................................................ 0.018 - 0.076 mm (0.0007 - 0.003 in.) Maximum Diametral Clearance (wear limit) ................................................................................................................................... 0.102 mm (0.004 in.) MAIN BEARING JOURNALS Diameter .............................................................................................................................................. ................................................. 64 mm (2.519 in.) Maximum Out-of-Round and/or Taper ............................................................................................................................................ 0.025 mm (0.001 in.) Bearings for Service ........................................................................................................... ......................................................................................... Std. .............................................................................................................................................................. ...................................... 0.025 mm (0.001 in.) .................................................................................... ................................................................................................................ 0.051 mm (0.002 in.) .......... .............................................................................................................................................................. ............................ 0.076 mm (0.003 in.) .............................................................................................. ...................................................................................................... 0.254 mm (0.010 in.) .................... .............................................................................................................................................................. .................. 0.305 mm (0.012 in.) CONNECTING ROD JOURNALS Diameter .............................................................................................................................................. ................................................. 58 mm (2.283 in.) Maximum Out-of-Round and/or Taper ............................................................................................................................................ 0.025 mm (0.001 in.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1783 Crankshaft: Description and Operation The nodular iron crankshaft is supported by four main bearings, with number two being the thrust bearing. Crankshaft end sealing is provided by front and rear rubber seals. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1784 Crankshaft: Service and Repair DIAL INDICATOR 1. Mount a dial indicator to front of engine, locating probe on nose of crankshaft. 2. Move crankshaft all the way to the rear of its travel. 3. Zero the dial indicator. 4. Move crankshaft all the way to the front and read the dial indicator. Specifications: New Part: 0.09 to 0.24 mm (0.004 to 0.009 inch). FEELER GAUGE 1. Move crankshaft all the way to the rear of its travel using a lever inserted between a main bearing cap and a crankshaft cheek using care not to damage any bearing surface. Do not loosen main bearing cap. 2. Use a feeler gauge between number 2 thrust bearing and machined crankshaft surface to determine end play. Refer to Specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Locations Engine Block Heater: Locations The power cord is located behind the radiator grille. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Locations > Page 1788 Engine Block Heater: Description and Operation DESCRIPTION The engine block heater is available as an optional accessory on all models. The heater is operated by ordinary house current (110 Volt A.C.) through a power cord located behind the radiator grille. PURPOSE This provides easier engine starting and faster warm-up when vehicle is operated in areas having extremely low temperatures. The heater is mounted in a core hole (in place of a core hole plug) in the engine block, with the heating element immersed in coolant. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Locations > Page 1789 Engine Block Heater: Service and Repair REMOVAL 1. Drain coolant from radiator and cylinder block. 2. Remove power cord plug from heater. 3. Loosen screw in center of heater. Remove heater assembly. INSTALLATION 1. Thoroughly clean core hole and heater seat. 2. Insert heater assembly with element loop positioned upward. 3. With heater seated, tighten center screw securely to assure a positive seal. 4. Fill cooling system with coolant to the proper level, vent air, and inspect for leaks. Pressurize system with Radiator Pressure Tool before looking for leaks. 5. Install power cord plug to heater. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Service and Repair Expansion/Freeze Plug: Service and Repair REMOVAL Using a blunt tool such as a drift or a screwdriver and a hammer, strike the bottom edge of the cup plug. With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug. CAUTION: Do not drive cup plug into the casting as restricted cooling can result and cause serious engine Problems. INSTALLATION Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Lightly coat inside of cup plug hole with sealer. Make certain the new plug is cleaned of all oil or grease. Using proper drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5 mm (0.020 inch) inside the lead in chamfer. It is in not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle placed in service immediately. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Mounting Bolt ....................................................................................................................................... ................................................... 54 Nm (40 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1796 Harmonic Balancer - Crankshaft Pulley: Service and Repair CRANKSHAFT PULLEY REMOVAL 1. Disconnect battery. 2. Raise vehicle on hoist. 3. Remove right wheel ana inner splash shield. 4. Remove drive belt. Refer to Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair for procedure. Fig. 41 Removing Crankshaft Pulley 5. Remove crankshaft pulley Fig. 41. Fig. 42 Installing Crankshaft Pulley CRANKSHAFT PULLEY INSTALLATION 1. Install crankshaft pulley Fig. 42. 2. Install drive belt. Refer to Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair for installation procedure. B. Install inner splash shield and wheel. 4. Connect battery. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1797 Puller 1023 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Technical Service Bulletins > Engine - Piston Knock at Idle Piston: Technical Service Bulletins Engine - Piston Knock at Idle NO: 09-03-94 GROUP: Engine DATE: Apr. 1, 1994 SUBJECT: Engine Idle Piston Noise MODELS: 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1994 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1994 (LH) Concorde/intrepid/Vision NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 3.3L AND 3.8L ENGINE SYMPTOM/CONDITION: Cold start up piston knocking noise at idle that diminishes 3 to 5 minutes after start up. The condition is more prominent in low ambient temperatures and after the vehicle has set overnight. Similar symptoms are described in Technical Service Bulletin 09-21-93 dated Dec. 31, 1993, "Carbon Buildup on Top of Piston". Refer to this Bulletin for additional details. DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, and carbon buildup on the top of the piston is not evident, proceed with the following repair. PARTS REQUIRED: AR 4621978 Piston & Connecting Rod Assy. (use w/3.3L engine) AR 4621981 Piston & Connecting Rod Assy. (use w/3.8L engine) REPAIR PROCEDURE: This repair involves installing a new coated piston and connecting rod assembly. 1. Following the procedure outlined in the appropriate Service Manual, remove the engine piston and connecting rods. 2. Install the new coated piston and connecting rod assembly as outlined in the Service Manual. NOTE: HONING OF THE CYLINDER BORES IS NOT RECOMMENDED. DISCUSSION: The new pistons have a coating bonded only to the piston skirt that is black in appearance. This new coating replaces the previously used tin coating. Items of special interest include: 1. The new coated pistons are available in one size only and are serviced with the piston pin and connecting rod as an assembly. 2. The new coated piston connecting rod assembly can be used to service all models listed and can be replaced one at a time (complete engine sets are not required). 3. Tin coated pistons should not be used as replacements for the coated pistons. 4. The coating material is applied after the final piston machining process. Therefore, the step for measuring the outside diameter of the piston to determine size or piston to bore clearance is not required. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Technical Service Bulletins > Engine - Piston Knock at Idle > Page 1802 5. Measuring the inside diameter of the cylinder bore with a Bore Gauge is still required. Dial Cylinder Bore Indicator, Tool C-119 available from Miller Special Tools, is recommended. Follow the procedure outlined in the Service Manual. If the cylinder bore measures larger than 3.664 inches (93.059 mm) for the 3.3L Engine, or 3.782 inches (96.059 mm) for the 3.8L Engine, the cylinder block will require replacement. 6. Piston installation into the cylinder bore may require slightly more pressure than that required for non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit with the cylinder bore. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: 1990 - 1994 AC, AS, AY (W/3.3L or 3.8L Engine) Piston and Connecting Rod Replace Labor Operation No. 09-70-01-91 One - Front Bank 4.2 Hrs. 09-70-01-92 One - Rear Bank 4.5 Hrs. 09-70-01-93 One - Each Bank 6.0 Hrs. 09-70-01-94 Each Additional 0.5 Hrs. 09-70-01-63 A/C Equipped 0.2 Hrs. 09-70-01-64 Power Steering Equipped (AS Only) 0.2 Hrs. 1993 - 1994 LH (w/3.3L or 3.8L Engine) Piston and Connecting Rod Replace Labor Operation No. 09-70-01-95 One - Left Bank 4.1 Hrs. 09-70-01-96 One - Right Bank 3.7 Hrs. 09-70-01-97 One - Each Bank 5.2 Hrs. 09-70-01-98 Each Additional 0.5 Hrs. 09-70-01-63 A/C Equipped 0.3 Hrs. FAILURE CODE: 58 - Noisy Cold Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Technical Service Bulletins > Page 1803 Piston: Specifications PISTONS Type Material ....................................................................................................................................... ............................... Aluminum Alloy Tin Coated Clearance at Size Location .................................................................................................................................... 0.025 - 0.057 mm (0.001 - 0.0022 in.) Weight (Std. Only) ......................................................................................... ............................................................................................. 381 +/- 5 gms Pistons For Service ........ .............................................................................................................................................................. ............... Standard Only PISTON PINS Type .............................................................................................................................................................. Press Fit in Rod (Serviced as an Assembly) Diameter ........................................................................ .................................................................................................. 22.88 mm (0.9007 - 0.9009 in.) Length .................................................................................................................................................. ................... 67.25 - 67.75 mm (2.648 - 2.667 in.) Clearance in Piston, Light Thumb Push @ 70°F ........................................................................................................................... 0.006 - 0.019 mm (0.0002 - 0.0007 in.) Clearance in Rod ................................................................................................................................. ........................................................ (Interference) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Technical Service Bulletins > Page 1804 Piston: Description and Operation The pistons are cast aluminum alloy. Three rings are used. Piston pins, press fitted into place, join the pistons to forged steel connecting rods. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation Piston: Service and Repair Removal and Installation NOTE: Heads and Oil Pan have to be removed first. REMOVAL 1. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine; rotate crankshaft so that each connecting rod is centered in cylinder bore. 2. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them if necessary. 3. Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts. Push each piston and rod assembly out of cylinder bore. NOTE: Be careful not to nick crankshaft journals. 4. After removal, install bearing cap on the mating rod. INSTALLATION 1. Before installing pistons and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1807 with oil ring rail gap. 2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown. 3. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston and tighten with the special wrench. Be sure position of rings does not change during this operation. 4. Install connecting rod bolt protectors on rod bolts. 5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal. 6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. 7. The notch or groove on top of piston must be pointing toward front of engine. 8. Install rod caps. Install nuts on cleaned and oiled rod bolts and tighten nuts to 54 Nm (40 ft. lb.) Plus 1/4 turn. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1808 Piston: Service and Repair Disassembly and Assembly Fig. 22 Piston Measurements Fig. 23 Piston Ring Installation Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1809 Fig. 24 Piston Ring Installation Fig. 25 Ring End Gap Orientation When installing piston and rod assemblies notch in piston top must point toward front of engine. Refer to Fig. 22 through 25 for piston measurements and ring installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1810 Piston: Service and Repair Fitting Pistons The piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin at size location shown. Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line shown. Refer to specifications. Pistons and cylinder bores should be measured at normal room temperature, 70°F (21°C). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Type ..................................................................................................................................................... ..................................................... Press Fit Into Rod Diameter .......................................................... .................................................................................................................. 22.88 mm (0.9009 0.9007 inch) Length ............................................................................................................................. .......................................... 67.25 - 67.75 mm (2.648 - 2.667 inch) Clearance In Piston w/Light Thumb Push@70°F .................................................................................................. 0.006 - 0.019 mm (0.0002 - 0.0007 inch) Clearance In Rod ..................................................................................... ............................................................................................................ Interference Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications > Page 1814 Piston Pin: Description and Operation The piston pin rotates in the piston only, and is retained by the press interference fit of the piston pin in the connecting rod. The piston pin is not to be removed; damage to the piston may result. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications PISTON RINGS Number of Rings Per Piston ................................................................................................................ ............................................................................ 3 Compression ....................................................................................................................................... ....................................................................... 2 Oil ............................................................................. ................................................................................................................................................ 1 Oil Ring Type ..................................................................................................................................................... 3 Piece, Steel Rail, Chrome - Face Ring Width Compression ....................................................................................................................................................... 1.46 - 1.5 mm (0.0575 - 0.0591 in.) Oil - Steel Rails ........................................................................... ............................................................................................ 0.510 mm (0.0201 in.) Ring Gap Compression ................................................................................................................................................. 0.300 0.550 mm (0.0118 - 0.0217 in.) Oil - Steel Rails ............................................................................................................................................... 0.250 1.00 mm (0.0098 - 0.0394 in.) Ring Side Clearance Compression ................................................................................................................................................. 0.030 0.095 mm (0.0012 - 0.0037 in.) Oil - Steel Rails ............................................................................................................................................. 0.014 0.226 mm (0.0005 - 0.0089 in.) Service Rings - Ring Gap Compression ................................................................................................................................................. 0.300 0.550 mm (0.0018 - 0.0217 in.) Oil - Steel Rails ............................................................................................................................................... 0.250 1.00 mm (0.0098 - 0.0394 in.) Ring Side Clearance Compression ................................................................................................................................................. 0.030 0.095 mm (0.0012 - 0.0037 in.) Oil - Steel Rails ............................................................................................................................................. 0.014 0.226 mm (0.0005 - 0.0089 in.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Removal and Installation Piston Ring: Service and Repair Removal and Installation Fig. 17 Installing piston rings Fig. 18 Positioning ring end gaps Install piston rings as shown in Figs. 17 and 18. PISTON RING-REMOVAL 1. ID mark on face of upper and intermediate piston rings must point toward piston crown. Piston Rings - Removing Or Installing 2. Using a suitable ring expander, remove upper and intermediate piston rings. 3. Remove the upper oil ring side rail, lower oil ring side rail and then oil ring expander from piston. 4. Clean ring grooves of any carbon deposits. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Removal and Installation > Page 1820 Piston Ring: Service and Repair Fitting Piston Rings 1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 inch) from bottom of cylinder bore. Check gap with feeler gauge. Refer to specifications. 2. Check piston ring to groove clearance. Refer to specification. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments This engine uses hydraulic lash adjusters, no adjustment is necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fig 1 Intake Plenum Mounting Bolts Fuel Pressure Release Procedure - Typical WARNING: The fuel system is under constant pressure of approximately 48 psi (330 kPa), even when the engine is OFF. 1. Disconnect negative battery cable. 2. Loosen fuel tank filler cap to relieve fuel tank pressure. 3. Remove cap on fuel rail pressure test port (Fig. 1). 4. Place one end of fuel pressure release hose, tool C-4799-1 (or equivalent), in an approved gasoline container. Connect the other end of this hose to the fuel rail service port. Fuel pressure should bleed off into container. 5. Perform necessary fuel system service procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Rocker Arm and Shaft Rocker Arm Assembly: Specifications Rocker Arm and Shaft Bracket Bolt ......................................................................................................................................... ............................................... 28 Nm (250 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Rocker Arm and Shaft > Page 1832 Rocker Arm Assembly: Specifications Rocker Arm Bolts 250 in.lb Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1833 Rocker Arm Assembly: Description and Operation Rocker arms are installed on a rocker arm shaft attached to the cylinder head with four bolts and retainers. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1834 Rocker Arm Assembly: Service and Repair REMOVAL 1. Remove upper intake manifold assembly. Refer to Intake Manifold. 2. Disconnect spark plug wires by pulling on the boot straight out in line with plug. 3. Disconnect closed ventilation system. 4. Remove cylinder head cover and gasket. 5. Remove four rocker shaft bolts and retainers. 6. Remove rocker arms and shaft assembly. 7. If rocker arm assemblies are disassembled for cleaning or replacement, re-assemble rocker arms in their original position. INSTALLATION 1. Install rocker arm and shaft assemblies with the stamped steel retainers in the four positions, tighten to 28 Nm (250 in. lbs.). CAUTION: The rocker arm shaft should be torqued down slowly, starting with the center bolts. Allow 20 minutes tappet bleed down time after installation of the rocker shafts before engine operation. 2. Clean cylinder head cover gasket surface. Inspect cover for distortion and straighten if necessary. 3. Clean head rail if necessary. Install a new gasket and tighten cylinder head cover fasteners to 12 Nm (105 in. lbs.). 4. Install closed crankcase ventilation system. 5. Install spark plug wires. 6. Install upper intake manifold assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Cylinder Head Cover Bolts/Nuts 105 in.lb Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 1838 Valve Cover: Description and Operation The covers are sealed with steel reinforced silicon rubber gaskets. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications Type ..................................................................................................................................................... ............................................. Powdered Metal Inserts Guide Bore Diameter ................................................................................................................................................ 7.975 8.000 mm (0.314 - 0.315 inch) Intake Stem To Guide Clearance: New Valve .................................... ............................................................................................................................. 0.025 - 0.095 mm (0.001 - 0.003 inch) Maximum Allowed Rocking Method ................................................................................................................................................ 0.247 mm (0.010 inch) Exhaust Stem To Guide Clearance: New Valve ....................................................... .......................................................................................................... 0.051 - 0.175 mm (0.002 0.006 inch) Maximum Allowed Rocking Method ................................................................................................................................................ 0.414 mm (0.016 inch) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Maximum Runout ................................................................................................................................ .............................................. 0.760 mm (0.003 inch) Intake: Seat Angle ........................................................................................................................................... ............................................................ 45 - 45 1/2° Seat Width .......................................................... ....................................................................................................... 1.75 - 2.25 mm (0.069 - 0.088 inch) Exhaust: Seat Angle ........................................................................................................................................... ............................................................ 45 - 45 1/2° Seat Width .......................................................... ....................................................................................................... 1.50 - 2.00 mm (0.057 - 0.078 inch) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications > Page 1845 Valve Seat: Service and Repair NOTE: The valve seats have a 45 to 45-1/2 degree face angle. CAUTION: Remove metal from valve seat only. Do not remove metal from cylinder head. VALVE SEATS 1. When refacing valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained. 2. Measure the concentricity of valve seat using dial indicator. Total runout should not exceed 0.051 mm (0.002 inch) total indicator reading. 3. Inspect the valve seat using Prussian blue to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is transferred to top edge of valve face, lower valve seat with a 15 degree stone. If the blue is transferred to the bottom edge of valve face raise valve seat with a 65 degrees stone. NOTE: Valve seats which are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise cylinder head must be replaced. 4. When seat is properly positioned the width of intake seats should be 1.75 - 2.25 mm (0.69 0.088 inch). The width of the exhaust seats should be 1.50 - 2.00 mm (0.059 - 0.078 inch). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications > Page 1846 5. Check the valve spring installed height after refacing the valve and seat. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Number ................................................................................................................................................ .............................................................................. 12 Free Length ..................................................... ..................................................................................................................................... 48.5 mm (1.909 inch) Wire Diameter .................................................................................................................. ................................................................... 4.75 mm (0.187 inch) Number of Coils ............................ .............................................................................................................................................................. ...................... 6.8 Installed Height ............................................................................................................................................................. 41.2 - 42.7 mm (1.622 - 1.681 inch) Load When Compressed: Valve Closed ....................................................................................................................................... ...................................... 95 - 100 lbs. @1.570 inch Valve Open ......................................................... .................................................................................................................... 207 - 229 lbs. @1.169 inch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1850 Valve Spring: Description and Operation Unique beehive style valve spring are used with lightweight retainers for improved high RPM performance. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head On Valve Spring: Service and Repair Cylinder Head On 1. Perform fuel system pressure release procedure before attempting any repairs. 2. Disconnect negative battery cable. 3. Remove Air Cleaner Cover and hose assembly. 4. Remove upper Intake Manifold. 5. Remove cylinder head covers and spark plugs. 6. Remove connector wire from ignition coils. 7. Using suitable socket and flex handle at crankshaft pulley retaining screw, turn engine so the number 1 piston is at Top Dead Center on the compression stroke. 8. Remove rocker arms with rocker shaft and install a dummy shaft. The rocker arms should not be disturbed and left on shaft. 9. With air hose attached to spark plug adapter installed in number 1 spark plug hole, apply 90 to 100 psi air pressure (620.5 to 689 kPa). This is to hold valves into place while servicing components. 10. Using Tool C-4682, or equivalent compress valve spring and remove retainer valve locks and valve spring. 11. The intake valve stem seals should be pushed firmly and squarely over the valve guide using the valve stem as guide. Do Not Force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. CAUTION: Do not pinch seal between retainer and top of valve guide. 12. Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-2-3-4-5-6. Make sure piston in cylinder is at Top Dead Center (TDC) on the valve spring that is being covered. 13. Remove spark plug adapter tool. 14. Remove dummy shaft and install rocker shaft assembly and tighten screws to 28 Nm (250 inch lbs.). 15. Install cylinder head covers tighten screws to 14 Nm (120 inch lbs.) and connector to ignition coils. 16. Install Intake Manifold. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head On > Page 1853 Valve Spring: Service and Repair Inspection Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested. As an example; the compression length of the spring to be tested is 33.34 mm (1-5/16 inches). Turn table of Tool C-647, or equivalent until surface is in line with the 33.34 mm (1-5/16 inch) mark on the threaded stud and the zero mark on the front. Place shrine over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Refer to specifications to obtain specified height and allowable tensions. Discard the springs that do not meet specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1854 Valve Spring: Tools and Equipment Valve Spring Tester C-647 Valve Spring Compressor C-3422-B Valve Spring Compressor Adapter 6412 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Intake Valve: Stem Diameter ..................................................................................................................................... ........................................ 7.935 mm (0.3124 inch) Face Angle .......................................................... .................................................................................................................................................... 44 1/2° Margin .......................................................................................................................................... ................................................. 0.794 mm (0.031 inch) Head Diameter ............................................. ...................................................................................................................................... 45.5 mm (1.79 inch) Length ................................................................................................................................ .......................................................... 125.38 mm (4.936 inch) Lift (zero lash) .................................... ........................................................................................................................................... 10.16 mm (0.400 inch) Minimum Valve Length After Grinding Tip .............................................................................................................................. 124.892 mm (4.916 inch) Exhaust Valve: Stem Diameter ..................................................................................................................................... ........................................ 7.906 mm (0.3112 inch) Face Angle .......................................................... .................................................................................................................................................... 44 1/2° Margin .......................................................................................................................................... ............................................... 1.191 mm (0.0469 inch) Head Diameter ............................................. .................................................................................................................................... 37.5 mm (1.476 inch) Length .............................................................................................................................. ............................................................ 126.00 mm (4.964 inch) Lift (zero lash) .................................. ............................................................................................................................................. 10.16 mm (0.400 inch) Minimum Valve Length After Grinding Tip .............................................................................................................................. 125.512 mm (4.941 inch) Valve Timing: Intake Opens ....................................................................................................................................... ................................................................ 2° BTDC Intake Closes ...................................................... .............................................................................................................................................. 58° ABDC Exhaust Opens ......................................................................................................................... ......................................................................... 48° BBDC Exhaust Closes ........................................ .......................................................................................................................................................... 12° ATDC Valve Overlap ..................................................................................................................... .......................................................................................... 14° Intake Valve Duration ......................... .............................................................................................................................................................. ......... 240° Exhaust Valve Duration .................................................................................................... .......................................................................................... 240° Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1858 Valve: Testing and Inspection INSPECTION 1. Clean valves thoroughly and discard burned, warped and cracked valves. 2. Measure valve stems for wear. Refer to specifications. Valve stems are chrome plated and should not be polished. 3. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. 4. Measure valve stem guide clearance as follows: a. Install valve into cylinder head so it is 14 mm (0.551 inch) off the valve seat. A small piece of hose may be used to hold valve in place. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1859 b. Attach dial indicator Tool C-3339, or equivalent to cylinder head and set it at right angle of valve stem being measured. 5. Move valve to and from the indicator. Refer to specifications. 6. Ream the guides for valves with oversized stems if dial indicator reading is excessive or if the stems are scuffed or scored. 7. Service valves with oversize stems and over size seals are available in 0.16 mm (0.005 inch), 0.40 mm, (0.015 inch) and 0.80 mm (0.030 inch) oversize. NOTE: Oversize seals must be used with oversize valves. 8. Reamers to accommodate the oversize valve stem are shown. 9. Slowly turn reamer by hand and clean guide thoroughly before installing new valve. Do not attempt to ream the valve guides from standard directly to 0.80 mm (0.030 inch) Use step procedure of 0.15 mm (0.005 inch), 0.40 mm (0.015 inch) and 0.80 mm (0.030 inch) so valve guides may be reamed true in relation to the valve seat. After reaming guides, the seat runout should be measured and resurfaced if necessary. NOTE: Replace cylinder head if guide does not clean up with 0.80 mm (0.030 inch) oversize reamer, or if guide is loose in cylinder head. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation Valve: Service and Repair Removal and Installation REMOVAL 1. With cylinder head removed, compress valve springs using Valve Spring Compressor Tool C-3422-B with adapter 6412, or equivalent as shown. 2. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. 3. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure installation in original location. INSTALLATION 1. Coat valve stems with clean engine oil and insert them in cylinder head. 2. Check valve tip to spring seat dimensions A after grinding the valve seats or faces. Grind valve tip to give 49.541 - 51.271 mm (1.950 - 2.018 inch) over spring seat when installed in the head. Check valve tip for scoring, if necessary, the tip chamfer should be reground to prevent seal damage when the valve is installed. 3. Install valve spring seat spacer on head. 4. Install new cup seals on all valve stems and over valve guides. Install valve springs and valve retainers. 5. Compress valve springs with Valve Spring Compressor Tool C-3422-B, with adapter 6412, or equivalents install locks and release tool. If valves and/or seats are reground, measure the installed height of springs dimension B. make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 1-19/32 inches, (40.6 mm), install a 1/32 inch (0.794 mm) spacer in head counterbore Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1862 to bring spring height back to normal 1-17/32 - 1-19/32 inch (39.1 - 40.6 mm). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1863 Valve: Service and Repair Refacing Valves and Valve Seats The intake and exhaust valves have a 44-1/2 to 45 degree face angle. Inspect the remaining margin after the valves are refaced Refer to specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 070294A > Dec > 94 > Serpentine Drive Belt - Comes Off Pulleys Drive Belt: Customer Interest Serpentine Drive Belt - Comes Off Pulleys NO.: 07-02-94 Rev. A GROUP: Cooling DATE: Dec. 23, 1994 SUBJECT: Serpentine Drive Belt Comes Off Pulleys NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-02-94, DATED MAR. 4, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ADD 1995 AND ES VEHICLES AND ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1991 - **1995** (AS) Town & Country/Caravan/Voyager **1992 - 1995 (ES) Chrysler Voyager (European Market)** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: If the vehicle is driven through deep or drifted snow the serpentine drive belt may be forced off of its pulleys by snow coming in between the belt and the pulleys. DIAGNOSIS: Determine the road conditions the driver of the vehicle was encountering at the time the serpentine belt came off. Verify all of the pulleys are in proper alignment and pulleys and accessories are properly attached. If the driver of the vehicle indicates deep or drifted snow may have been a factor in the serpentine belt coming off its pulleys and any pulley mis-alignment and/or accessory/pulley attachment problem has been corrected, perform the following repair procedure. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves attaching a shield to the power steering pump and the power steering pump bracket that prevents snow from coming in between the serpentine belt and the power steering pump pulley. 1. Re-install the serpentine drive belt or replace with a new belt if damaged. 2. Remove the second from the bottom bolt that attaches the power steering pump bracket to the engine block. NOTE: ON EARLY BUILT 1991 MODEL VEHICLES, IF THERE IS A TAB ON THE POWER STEERING BRACKET THAT INTERFERES WITH THE FIT OF THE SHIELD, IT IS NECESSARY TO SAW IT OFF. DO NOT BREAK THE TAB OFF. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 070294A > Dec > 94 > Serpentine Drive Belt - Comes Off Pulleys > Page 1873 3. Position the shield (P/N 4773892) so its mounting hole (closest to the oval cutout of the shield) goes over the stud on the back of the power steering pump and the other mounting hole is aligned with the hole of power steering pump bracket from which the bolt was removed in step 2. 4. Install the lower power steering pump bracket attaching bolt and torque to 30 - 50 ft.lbs. (40.7 67.8 N-m). 5. Install nut/washer (P/N 6501926) on the stud at the back of the power steering pump and torque to 30 - 50 ft.lbs. (40.7 - 67.8 N-m). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 07-20-15-95 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 070294A > Dec > 94 > Serpentine Drive Belt - Comes Off Pulleys Drive Belt: All Technical Service Bulletins Serpentine Drive Belt - Comes Off Pulleys NO.: 07-02-94 Rev. A GROUP: Cooling DATE: Dec. 23, 1994 SUBJECT: Serpentine Drive Belt Comes Off Pulleys NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-02-94, DATED MAR. 4, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ADD 1995 AND ES VEHICLES AND ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1991 - **1995** (AS) Town & Country/Caravan/Voyager **1992 - 1995 (ES) Chrysler Voyager (European Market)** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: If the vehicle is driven through deep or drifted snow the serpentine drive belt may be forced off of its pulleys by snow coming in between the belt and the pulleys. DIAGNOSIS: Determine the road conditions the driver of the vehicle was encountering at the time the serpentine belt came off. Verify all of the pulleys are in proper alignment and pulleys and accessories are properly attached. If the driver of the vehicle indicates deep or drifted snow may have been a factor in the serpentine belt coming off its pulleys and any pulley mis-alignment and/or accessory/pulley attachment problem has been corrected, perform the following repair procedure. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves attaching a shield to the power steering pump and the power steering pump bracket that prevents snow from coming in between the serpentine belt and the power steering pump pulley. 1. Re-install the serpentine drive belt or replace with a new belt if damaged. 2. Remove the second from the bottom bolt that attaches the power steering pump bracket to the engine block. NOTE: ON EARLY BUILT 1991 MODEL VEHICLES, IF THERE IS A TAB ON THE POWER STEERING BRACKET THAT INTERFERES WITH THE FIT OF THE SHIELD, IT IS NECESSARY TO SAW IT OFF. DO NOT BREAK THE TAB OFF. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 070294A > Dec > 94 > Serpentine Drive Belt - Comes Off Pulleys > Page 1879 3. Position the shield (P/N 4773892) so its mounting hole (closest to the oval cutout of the shield) goes over the stud on the back of the power steering pump and the other mounting hole is aligned with the hole of power steering pump bracket from which the bolt was removed in step 2. 4. Install the lower power steering pump bracket attaching bolt and torque to 30 - 50 ft.lbs. (40.7 67.8 N-m). 5. Install nut/washer (P/N 6501926) on the stud at the back of the power steering pump and torque to 30 - 50 ft.lbs. (40.7 - 67.8 N-m). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 07-20-15-95 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1880 Drive Belt: Specifications Belt tension is controlled automatically by the dynamic tensioner. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > With A/C Fig. 34 Serpentine Drive Belt Routing Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > With A/C > Page 1883 Drive Belt: Diagrams Without A/C Fig. 34 Serpentine Drive Belt Routing This image shows an air conditioning compressor. The OE does not provide an image for accessory belt routing without A/C. This article is included here to provide the accessory drive belt routing for a non-air conditioned vehicle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 1884 Drive Belt: Description and Operation The accessory drive system utilizes two different style of drive belts. The conventional V-belt and the Poly-v belt are used to drive the generator, air conditioning compressor, power steering pump and water pump. Satisfactory performance of these belts depends on belt condition and proper belt tension. Belt tensioning should be performed with the aid of a Burroughs gauge special tool C-4162, or equivalent. Because of space limitations in the engine compartment, the use of the gauge may be restricted. Raise the vehicle on a hoist and then remove the splash shield to gain access to the drive belts. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 1885 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 1886 Drive Belt: Adjustments PROPER BELT TENSION Satisfactory performance of the belt driven accessories depends on proper belt tension. Belt tensioning should be performed with the aid of a Burroughs gauge Special Tool C-4162. Because of space limitations in the engine compartment, the use of the gauge may be restricted. Raise the vehicle on a hoist and the remove the splash shield to gain access to the drive belts. BELT TENSION GAUGE METHOD Use belt tensioning Special Tool Kit C-4162 for: CAUTION: The Burroughs gauge for the Poly-V belt is not to be used on the V-belt. These gauges are not interchangeable. For Conventional V-belts - affix the Burroughs gauge (Special Tool C-4162) to the belt. Adjust the belt tension for New or Used belt as prescribed in specifications. For a Poly-V Belt - affix the Poly-V Burroughs gauge to the belt and then apply specified tension to the belt as prescribed in specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Removal and Installation Drive Belt: Service and Repair Removal and Installation Fig. 6 Accessory Drive Belt REMOVE/INSTALL The Poly-V Drive belt is provided with a dynamic tensioner Fig. 6 to maintain proper belt tension. To remove or install this belt: 1. Raise vehicle on hoist. 2. Remove right front splash shield. 3. Release tension by rotating the tensioner clockwise Fig. 6. 4. Reverse above procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1889 Drive Belt: Service and Repair Cleaning and Inspection When inspecting serpentine drive belts, small cracks that run across the ribbed surface of the belt from rib to rib, are considered normal. These are not reasons to replace the belt. However, cracks running along the rib (not across) are not normal. Any belt with cracks running along the rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Page 1890 Belt Tension Gauge C-4162 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair Drive Belt Tensioner: Service and Repair The tensioner is attached by stud through the bracket with a nut on the back of the bracket. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Specifications Engine Accessory Bracket: Specifications A/C Compressor Bracket to Water Pump Bolt ......................................................................................................................................... 41 Nm (30 ft. lbs.) A/C Compressor To Bracket Bolt ............................................................................................................................................................. 67 Nm (50 ft. lbs.) A/C Compressor Support Bolts .............................................................................. .................................................................................. 41 Nm (30 ft. lbs.) Generator: Adjusting Strap Bolt ............................................................................................................................. ........................................... 23 Nm (200 inch lbs.) Adjusting Strap Mounting Bolt ............................................................................................................................................................. 41 Nm (30 ft. lbs.) Bracket Bolt ............................................................................................................ .............................................................................. 41 Nm (30 ft. lbs.) Mounting Pivot Nut .................. ............................................................................................................................................................ 41 Nm (30 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 091494 > Aug > 94 > Engine Mount - Squeak/Clunk Noise Technical Service Bulletin # 091494 Date: 940809 Engine Mount - Squeak/Clunk Noise NO.: 09-14-94 GROUP: Engine DATE: Sep. 9, 1994 SUBJECT: Squeak Noise When Turning and/or Clunk Noise When Shifting Into Reverse MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: 1. Squeak noise from the engine compartment which occurs during a low speed right turn. The squeak noise becomes more pronounced when the road surface is rough and/or while accelerating during the turn. 2. Squeak noise from the engine compartment which occurs during a low speed left turn. The squeak noise becomes more pronounced when the road surface is rough and/or while accelerating during the turn. 3. Clunk noise from the engine compartment which occurs when shifting transmission into reverse. Symptom/Condition 1 The squeak noise during right turns can be caused by the top edge of the left engine mount rubbing on the left frame rail bracket, or the outside of the front engine mount rubbing on the drivers side of the bracket which ties it to the engine. Inspect the left engine mount visually for a bare metal spot where the paint has been rubbed off of the engine bracket and by the relative position between the core of the rubber isolator and the nub on the gold "slider tube" (Refer to Figure 1). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 091494 > Aug > 94 > Engine Mount - Squeak/Clunk Noise > Page 1905 Inspect the front engine mount visually for a bare metal spot where the paint has been rubbed off of the left rail bracket (Refer to Figure 2). If the bare metal spot is present, perform repair procedure 1. Symptom/Condition 2 The squeak noise during left turns can be caused by the outside of the front engine mount rubbing on the passenger side of the bracket which ties it to the engine. Inspect the front engine mount visually for a bare metal spot where the paint has been rubbed off of the engine bracket (Refer to Figure 3). If the bare metal spot is present, perform repair procedure 1. Symptom/Condition 3 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 091494 > Aug > 94 > Engine Mount - Squeak/Clunk Noise > Page 1906 A clunk noise while shifting into reverse can be caused by relative movement between the metal can which the front engine mount isolator is molded around and the square metal can which is welded to the bracket which the isolator can is pressed into (Refer to Figure 4). To diagnose the front mount, fully apply the parking brake and service brakes. Watch and listen to the front mount while an assistant shifts the transmission into reverse and slowly increases the throttle opening (brake torque). It will be visually apparent if the inner isolator can moves relative to the outer can causing an audible clunk noise during this maneuver. If the vehicle exhibits this condition, perform repair procedure 2. Repair Procedure 1 This procedure corrects Symptom/Condition 1 & 2 by adjusting the right and front engine mounts. 1. Verify the front driveshaft lengths (engine centering) are within specification. Measure the length from the inner edge of the outboard boot to the inner edge of the inboard boot on both driveshafts (Refer to Figure 5). This measurement must be taken at the bottom (six o'clock position) of the driveshafts while the vehicle is in a normal parked, front wheels straight ahead position. Driveshaft Length Specifications: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 091494 > Aug > 94 > Engine Mount - Squeak/Clunk Noise > Page 1907 2. Remove the load on the engine mounts by carefully supporting the engine and transmission with a floor jack. 3. Loosen the 2 bolts attaching the right engine mount insulator to the frame rail. 4. Loosen the screw and 2 nuts attaching the front engine mount bracket to the front lower crossmember. 5. If the driveshaft lengths are within specification, skip to step 6. Otherwise, loosen the left engine mount through bolt so it is still engaged in the threads weld nut of the rail bracket. Pry the engine right or left as required to achieve the proper driveshaft lengths. Make sure the left engine mount two piece gold color slider tube moves in relation to the aluminum core for the adjustment to be effective. 6. Position the right engine mount insulator so an outboard gap "A" of .020 in. (0.5 mm) is achieved between the outboard snubber of the insulator and the yoke bracket (Refer to Figure 6). Torque the 2 right engine mount insulator attaching bolts to 50 ft.lbs. (68 N-m). 7. Position the front engine mount isolator to achieve a minimum clearance of 0.3 in. (7 mm) on the drivers side and 0.5 in. (12 mm) on the Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 091494 > Aug > 94 > Engine Mount - Squeak/Clunk Noise > Page 1908 passengers side between the isolator and the engine bracket (Refer to Figure 7). NOTE: IT MAY NECESSARY TO LENGTHEN THE SLOTS IN THE FRONT MOUNT ISOLATOR BY 0.1 in. (2 mm) TO ACHIEVE PROPER CLEARANCE. THE SLOTS CAN BE LENGTHENED, IF NECESSARY, BY USING A RAT TAIL FILE. Torque the screw and 2 nuts attaching the front engine mount isolator to the lower front crossmember to 40 ft.lbs. (54 N-m). 8. If driveshaft length adjustment was required, torque the left engine mount through bolt to 55 ft.lbs. (75 N-m) and recheck driveshaft lengths. 9. Apply touch up paint to any bare metal spots. Repair Procedure 2 This procedure corrects Symptom/Condition 3 by replacing the front engine mount isolator. 1. Support the engine and transmission assembly with a floor jack so it will not rotate when the mount is disconnected from the lower front crossmember. 2. Remove the screw and 2 nuts attaching the front engine mount insulator to the lower front crossmember. 3. Remove the through bolt attaching the front engine mount insulator to the front engine bracket and discard the insulator. 4. Select the appropriate front engine mount insulator from the Parts Required section of this bulletin. Install the through bolt attaching the front engine mount insulator to the front engine bracket. Torque the through bolt to 50 ft. lbs. (68 Nm). Position the replacement front engine mount isolator to achieve a minimum clearance of 0.3 in. (7 mm) on the drivers side and 0.5 in. (12 mm) on the passengers side between the isolator and the engine bracket (Refer to Figure 7). NOTE: IT MAY NECESSARY TO LENGTHEN THE SLOTS IN THE FRONT MOUNT ISOLATOR BY 0.08 in. (2 mm) TO ACHIEVE PROPER CLEARANCE. THE SLOTS CAN BE LENGTHENED, IF NECESSARY, BY USING A RAT TAIL FILE. 5. Torque the screw and 2 nuts attaching the front engine mount isolator to the lower front crossmember to 40 ft.lbs. (54 N-m). Policy POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 09-40-23-92 (Condition 1) 0.7 Hrs. 09-40-23-91 (Condition 2) 0.6 Hrs. FAILURE CODE: XX - Service Adjustment (Condition 1) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 091494 > Aug > 94 > Engine Mount - Squeak/Clunk Noise > Page 1909 P8 - New Part (Condition 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 091494 > Aug > 94 > Engine Mount - Squeak/Clunk Noise Technical Service Bulletin # 091494 Date: 940809 Engine Mount - Squeak/Clunk Noise NO.: 09-14-94 GROUP: Engine DATE: Sep. 9, 1994 SUBJECT: Squeak Noise When Turning and/or Clunk Noise When Shifting Into Reverse MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: 1. Squeak noise from the engine compartment which occurs during a low speed right turn. The squeak noise becomes more pronounced when the road surface is rough and/or while accelerating during the turn. 2. Squeak noise from the engine compartment which occurs during a low speed left turn. The squeak noise becomes more pronounced when the road surface is rough and/or while accelerating during the turn. 3. Clunk noise from the engine compartment which occurs when shifting transmission into reverse. Symptom/Condition 1 The squeak noise during right turns can be caused by the top edge of the left engine mount rubbing on the left frame rail bracket, or the outside of the front engine mount rubbing on the drivers side of the bracket which ties it to the engine. Inspect the left engine mount visually for a bare metal spot where the paint has been rubbed off of the engine bracket and by the relative position between the core of the rubber isolator and the nub on the gold "slider tube" (Refer to Figure 1). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 091494 > Aug > 94 > Engine Mount - Squeak/Clunk Noise > Page 1915 Inspect the front engine mount visually for a bare metal spot where the paint has been rubbed off of the left rail bracket (Refer to Figure 2). If the bare metal spot is present, perform repair procedure 1. Symptom/Condition 2 The squeak noise during left turns can be caused by the outside of the front engine mount rubbing on the passenger side of the bracket which ties it to the engine. Inspect the front engine mount visually for a bare metal spot where the paint has been rubbed off of the engine bracket (Refer to Figure 3). If the bare metal spot is present, perform repair procedure 1. Symptom/Condition 3 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 091494 > Aug > 94 > Engine Mount - Squeak/Clunk Noise > Page 1916 A clunk noise while shifting into reverse can be caused by relative movement between the metal can which the front engine mount isolator is molded around and the square metal can which is welded to the bracket which the isolator can is pressed into (Refer to Figure 4). To diagnose the front mount, fully apply the parking brake and service brakes. Watch and listen to the front mount while an assistant shifts the transmission into reverse and slowly increases the throttle opening (brake torque). It will be visually apparent if the inner isolator can moves relative to the outer can causing an audible clunk noise during this maneuver. If the vehicle exhibits this condition, perform repair procedure 2. Repair Procedure 1 This procedure corrects Symptom/Condition 1 & 2 by adjusting the right and front engine mounts. 1. Verify the front driveshaft lengths (engine centering) are within specification. Measure the length from the inner edge of the outboard boot to the inner edge of the inboard boot on both driveshafts (Refer to Figure 5). This measurement must be taken at the bottom (six o'clock position) of the driveshafts while the vehicle is in a normal parked, front wheels straight ahead position. Driveshaft Length Specifications: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 091494 > Aug > 94 > Engine Mount - Squeak/Clunk Noise > Page 1917 2. Remove the load on the engine mounts by carefully supporting the engine and transmission with a floor jack. 3. Loosen the 2 bolts attaching the right engine mount insulator to the frame rail. 4. Loosen the screw and 2 nuts attaching the front engine mount bracket to the front lower crossmember. 5. If the driveshaft lengths are within specification, skip to step 6. Otherwise, loosen the left engine mount through bolt so it is still engaged in the threads weld nut of the rail bracket. Pry the engine right or left as required to achieve the proper driveshaft lengths. Make sure the left engine mount two piece gold color slider tube moves in relation to the aluminum core for the adjustment to be effective. 6. Position the right engine mount insulator so an outboard gap "A" of .020 in. (0.5 mm) is achieved between the outboard snubber of the insulator and the yoke bracket (Refer to Figure 6). Torque the 2 right engine mount insulator attaching bolts to 50 ft.lbs. (68 N-m). 7. Position the front engine mount isolator to achieve a minimum clearance of 0.3 in. (7 mm) on the drivers side and 0.5 in. (12 mm) on the Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 091494 > Aug > 94 > Engine Mount - Squeak/Clunk Noise > Page 1918 passengers side between the isolator and the engine bracket (Refer to Figure 7). NOTE: IT MAY NECESSARY TO LENGTHEN THE SLOTS IN THE FRONT MOUNT ISOLATOR BY 0.1 in. (2 mm) TO ACHIEVE PROPER CLEARANCE. THE SLOTS CAN BE LENGTHENED, IF NECESSARY, BY USING A RAT TAIL FILE. Torque the screw and 2 nuts attaching the front engine mount isolator to the lower front crossmember to 40 ft.lbs. (54 N-m). 8. If driveshaft length adjustment was required, torque the left engine mount through bolt to 55 ft.lbs. (75 N-m) and recheck driveshaft lengths. 9. Apply touch up paint to any bare metal spots. Repair Procedure 2 This procedure corrects Symptom/Condition 3 by replacing the front engine mount isolator. 1. Support the engine and transmission assembly with a floor jack so it will not rotate when the mount is disconnected from the lower front crossmember. 2. Remove the screw and 2 nuts attaching the front engine mount insulator to the lower front crossmember. 3. Remove the through bolt attaching the front engine mount insulator to the front engine bracket and discard the insulator. 4. Select the appropriate front engine mount insulator from the Parts Required section of this bulletin. Install the through bolt attaching the front engine mount insulator to the front engine bracket. Torque the through bolt to 50 ft. lbs. (68 Nm). Position the replacement front engine mount isolator to achieve a minimum clearance of 0.3 in. (7 mm) on the drivers side and 0.5 in. (12 mm) on the passengers side between the isolator and the engine bracket (Refer to Figure 7). NOTE: IT MAY NECESSARY TO LENGTHEN THE SLOTS IN THE FRONT MOUNT ISOLATOR BY 0.08 in. (2 mm) TO ACHIEVE PROPER CLEARANCE. THE SLOTS CAN BE LENGTHENED, IF NECESSARY, BY USING A RAT TAIL FILE. 5. Torque the screw and 2 nuts attaching the front engine mount isolator to the lower front crossmember to 40 ft.lbs. (54 N-m). Policy POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 09-40-23-92 (Condition 1) 0.7 Hrs. 09-40-23-91 (Condition 2) 0.6 Hrs. FAILURE CODE: XX - Service Adjustment (Condition 1) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 091494 > Aug > 94 > Engine Mount - Squeak/Clunk Noise > Page 1919 P8 - New Part (Condition 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 1920 Engine Mount: Adjustments 1. Remove the load on the engine motor mounts by carefully supporting the engine and transmission assembly with a floor jack. 2. Loosen the right engine mount insulator vertical fastener and the fore and aft fasteners, and the front engine mount bracket to front crossmember screws. 3. Pry the engine right or left as required to achieve the proper drive shaft assembly length. 4. Tighten engine mounts and fasteners in the following order: a. Right engine mount insulator vertical bolts to 102 Nm (75 ft. lbs.) and the fore and aft bolts to 150 Nm (110 ft. lbs.). b. Front engine mount screws to 54 Nm (40 ft. lbs.) the clearance between the snubbers and the engine should be 2 mm (0.078 inch) each side. c. Left engine mount through bolt to 75 Nm (55 ft. lbs.). 5. Recheck driveshaft length. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Engine Mount: Service and Repair Engine Mount FRONT 1. Raise and support vehicle. Support engine and transmission assembly with jack. Fig. 2 Front Engine Mount Replacement 2. Remove front engine mount through bolt from insulator and front crossmember mounting bracket, Fig. 2. 3. Remove six screws from air dam to access front mount screws. 4. Remove front engine mount screws and remove insulator assembly. 5. Remove front mounting bracket. 6. Reverse procedure to install, noting the following: a. Torque bolts No. 1 and No. 5, Fig. 2, first to 40 ft. lbs., then torque bolts No. 2, No. 3 and No. 4 to 80 ft. lbs. b. Torque air dam screws to 8.75 ft. lbs. LEFT 1. Raise and support vehicle, then remove left front wheel. 2. Support transaxle with suitable jack. 3. Remove insulator through bolt from left engine mount. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount > Page 1923 Fig. 3 Left Side Engine Mount Replacement 4. Remove mount to transmission fasteners, then remove mount, Fig. 3. 5. Reverse procedure to install, noting the following: a. Tighten attaching nuts and bolts to specifications. b. Before tightening through bolt ensure there is no load on insulator. RIGHT 1. Remove purge duty solenoid and wiring harness from engine mount bracket. Fig. 4 Right Side Engine Mount Replacement Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount > Page 1924 2. Remove two right engine mount insulator vertical bolts from frame rail and loosen horizontal bolt. Do not remove large nut at end of core, Fig. 4. 3. Support transaxle with suitable jack. 4. Remove vertical and horizontal bolts from engine side bracket, then remove mount assembly. 5. Reverse procedure to install. Tighten to specifications. REAR 1. Raise and support vehicle, then remove left front wheel. 2. Support transmission with transmission jack. 3. Remove insulator through bolt from mount and rear suspension crossmember. Fig. 5 Rear Engine Mount Replacement 4. Remove four transmission mount bolts and the mount, Fig. 5. 5. Reverse procedure to install. Torque through bolt to 55 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount > Page 1925 Engine Mount: Service and Repair Rubber Insulators Insulator location on (right side) is adjustable to allow right/left drive train adjustment in relation to drive shaft assembly length. Check and reposition right engine mount insulator. See Adjustments. Adjust drive train position, if required, for the following conditions: a. Drive shaft distress. b. Any front end structural damage (after repair). c. Insulator replacement. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Testing and Inspection Engine Oil Pressure: Testing and Inspection Check oil pressure using gauge at oil pressure switch location. Oil pressure should be 34.47 kPa (5 psi) at idle or 205 to 551 kPa (30 to 80 psi) at 3000 RPM. 1. Remove pressure sending unit and install oil pressure gauge. CAUTION: If oil pressure is 0 at idle, do not run engine at 3000 RPM. 2. Warm engine at high idle until thermostat opens. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications Drain Plug ............................................................................................................................................ ..................................................... 34 Nm (25 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications Engine Oil: Specifications TYPE.................................................................................................................................................... ...............................................................SG, SG/CD* *Preferred with Turbo engine SG/CD required for 1993 Turbo engine. CAPACITY, Refill: 3.3L Concorde, Intrepid, Vision ...................................................................................................................................................... 4.3 Liters 4.5 Quarts 3.5L, all ................................................................................................................................................ ........................................... 4.8 Liters 5.0 Quarts All others .............................................................................................................................................. ........................................... 3.8 Liters 4.0 Quarts Capacity shown is without filter. When replacing filter, additional oil may be needed All engine. above 0°F (-18°C)............................................................................................................... .....................................................................10W-30* 2.5L Van, 3.5L & Turbo below 32°F (0°C)........ .........................................................................................................................................................5 W-30‡ Non-Turbo ex. 2.5L Van below 100°F (38°C)....................................................................................... ........................................................................5W-30 *Preferred in all Turbo, 2.5L & 3.5L ‡Preferred in all non-Turbo ex. 2.5L Van Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service Precautions > Technician Safety Information Engine Oil: Technician Safety Information 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 GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service Precautions > Technician Safety Information > Page 1938 Engine Oil: Vehicle Damage Warnings CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service Precautions > Page 1939 Engine Oil: Description and Operation CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result. API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certified or an oil that conforms to the API Service Grade SH or SH/CD. SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. SAE 30 specifies a single viscosity engine oil. Engine oils also have multiple viscosities. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation. ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. They are designated as either ENERGY CONSERVING or ENERGY CONSERVING II. CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans. ENGINE OIL ADDITIVES In some instances, such as infrequent operation, short trip driving, and during break-in after a major overhaul, addition of special materials containing anti-rust and anti-scuff additives are beneficial. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service Precautions > Page 1940 Engine Oil: Testing and Inspection CHECKING OIL LEVEL To assure proper engine lubrication, the engine oil must be maintained at the correct level. Check the oil level at regular intervals, such as every fuel stop. The best time to check the oil level is about 5 minutes after a fully warmed-up engine is shut off, or before starting the vehicle after it has sat overnight. Checking the oil while the vehicle is on level ground, will improve the accuracy of the oil level readings. Maintain the oil level between the MIN and MAX markings on the dipstick. Adding one quart of oil when the reading is at the MIN mark will result in a MAX reading on these engines. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service Precautions > Page 1941 Engine Oil: Service and Repair CHANGING ENGINE OIL Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. Refer. to Hoisting and Jacking Recommendations. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 6. Install drain plug in crankcase. 7. Lower vehicle and fill crankcase with specified type and amount of engine oil. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair Oil Filter: Service and Repair CAUTION: When servicing the oil filter avoid deforming the filter can by installing the remove/install tool band strap against the can-to-base lock seam. The lock seam joining the can to the base is reinforced by the base plate. 1. Using Tool C-4065, or equivalent, turn filter counterclockwise to remove from base. Properly discard filter. 2. Wipe base clean, then inspect gasket contact surface. 3. Lubricate gasket of new filter with clean engine oil. 4. Install new filter until gasket contacts base. Tighter filter 1 turn or 20 Nm (15 ft. Lbs.). Use filter wrench if necessary. 5. Start engine and check for leaks. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Page 1945 Oil Filter Wrench C-4065 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications Oil Filter Adapter: Specifications Mounting Bolt ....................................................................................................................................... ................................................... 41 Nm (30 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolts 105 in.lb Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal and Installation Oil Pan: Service and Repair Removal and Installation REMOVAL 1. Disconnect battery negative cable, remove engine oil dipstick. 2. Raise vehicle. Drain engine-oil. 3. Remove oil pan screws and remove oil pan. 4. Remove screw for oil pick-up tube and remove pick-up tube. INSTALLATION 1. Install oil pick-up tube into Chain Case Cover tighten screw to 28 Nm (250 inch lbs.). 2. Apply a 1/8 inch bead of Mopar (R) Silicone Rubber Adhesive Sealant or equivalent, at the parting line of the chain case cover and the rear seal retainer. 3. Use a new pan gasket. 4. Install pan and tighten screws to 12 Nm (105 inch lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal and Installation > Page 1957 5. Lower vehicle and install oil dipstick. 6. Connect battery negative cable. 7. Fill crankcase with oil to proper level. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal and Installation > Page 1958 Oil Pan: Service and Repair Cleaning and Inspection 1. Clean oil pan in solvent and wipe dry with a clean cloth. Clean all gasket material from mounting surfaces of pan and block. 2. Inspect oil drain plug and plug hole for stripped or damaged threads and repair as necessary. Install a new drain plug gasket. Tighten to 27 Nm (20 ft. lbs.). 3. Inspect oil pan mounting flange for bends or distortion. Straighten flange if necessary. 4. Clean oil screen and pipe in clean solvent. Inspect condition of screen. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1964 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1965 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1966 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1967 Oil Pressure Sender: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1968 Engine Oil Pressure & Temp. System With Transmission Control Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Cover > Component Information > Specifications Oil Pump Cover: Specifications Mounting Bolts ..................................................................................................................................... ............................................... 12 Nm (105 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications Oil Pick Up/Strainer: Specifications Mounting Bolt ....................................................................................................................................... .............................................. 28 Nm (250 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Testing and Inspection Engine Oil Pressure: Testing and Inspection Check oil pressure using gauge at oil pressure switch location. Oil pressure should be 34.47 kPa (5 psi) at idle or 205 to 551 kPa (30 to 80 psi) at 3000 RPM. 1. Remove pressure sending unit and install oil pressure gauge. CAUTION: If oil pressure is 0 at idle, do not run engine at 3000 RPM. 2. Warm engine at high idle until thermostat opens. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Mounting Bolts ..................................................................................................................................... ............................................... 23 Nm (200 inch lbs.) Plenum Bolt ...................................................... ................................................................................................................................... 28 Nm (250 inch lbs.) Plenum Support Bracket ...................................................................................................... ..................................................................... 54 Nm (40 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1982 Intake Manifold: Description and Operation The intake manifold is a tuned two-piece semi-permanent mold aluminum casting with individual primary runners leading from a plenum to the cylinders. The manifold is designed to boost torque in the 3600 rpm range and contributes to the engine's broad, flat torque curve, which was desired for excellent engine tractability, response and usable power output. The intake manifold is also cored with upper level EGR passages for balanced cylinder to cylinder EGR distribution. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1983 Intake Manifold: Testing and Inspection LEAKAGE DIAGNOSIS An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning. WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR LOOSE CLOTHING. 1. Start the engine. 2. Spray a small stream of water (Spray Bottle) at the suspected leak area. 3. If a change in RPM'S, the area of the suspected leak has been found. 4. Repair as required. GENERAL INSPECTION Check for: ^ Damage and cracks of each section. ^ Clogged water passages in end crossovers (if equipped). ^ Check for cylinder head mounting surface distortion using a straightedge and thickness gauge. CLEANING Remove the gasket material from the manifold surfaces. Be careful not to gouge or scratch the sealing surface. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1984 Intake Manifold: Service and Repair REMOVAL 1. Perform fuel system pressure release procedure, as follows. NOTE: The fuel system is under a constant pressure of approximately 330 kPa (48 psi). Before servicing the fuel pump, fuel lines, fuel filter, throttle body or fuel injector, the fuel system pressure must be released. Fig. 1 Injector Harness Connector ^ Loosen fuel filler cap to release fuel tank pressure. ^ Disconnect injector wiring harness, from engine harness. ^ Connect a jumper wire to ground terminal Number 1 of the injector harness Fig. 1 to engine ground. ^ Connect a jumper wire to the positive terminal Number 2 of the injector harness Fig. 1 and touch the battery positive post for no longer than 5 seconds. This releases system pressure. ^ Remove jumper wires. ^ Continue fuel system service. 2. Disconnect negative battery cable. Drain cooling system. Fig. 2 Throttle Body Assembly 3.3L 3. Remove air cleaner to throttle body hose assembly Fig. 2. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1985 Fig. 3 Throttle Cable Attachment 4. Remove throttle cable Fig. 3. Remove wiring harness from throttle cable bracket. Fig. 4 Electrical And Vacuum Connection To Throttle Body 5. Remove automatic idle speed (AIS) motor and throttle position sensor (TPS) wiring connectors from throttle body Fig. 4. 6. Remove vacuum hose harness from throttle body Fig. 4. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1986 Fig. 5 Electrical And Vacuum Connections To Intake Manifold 7. Remove PCV and brake booster hoses from air intake plenum Fig. 5 8. Remove EGR tube flange from intake plenum Fig. 5. 9. Disconnect Charge Temperature Sensor electrical connector. Remove vacuum harness connectors from intake plenum Fig. 5. 10. Remove cylinder head to intake plenum strut Fig. 5. Fig. 6 MAP Sensor Electrical Connector 11. Disconnect MAP Sensor and heated Oxygen Sensor electrical connection. Remove the engine mounted ground strap Fig. 6. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1987 Fig. 7 Quick Connect Fuel Fittings To Fuel Rail 12. Remove the fuel hose quick connect fittings from the fuel rail by using an open end wrench pushing in on the plastic ring located on the end of the fittings. Gently pull the fittings from the fuel rail Fig. 7. WARNING: Wrap a shop towel around hoses to catch any gasoline spillage during removal. Fig. 8 Ignition Coils 13. Remove direct ignition system (DIS) coils and alternator bracket to intake manifold bolt Fig. 8. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1988 Fig. 9 Intake Manifold Bolts 14. Remove intake manifold bolts and rotate manifold back over rear valve cover Fig. 9. Fig. 10 Fuel Rail Attaching Bolts 15. Cover intake manifold with suitable cover when servicing Fig. 10. 16. Remove vacuum harness connector from Fuel Pressure Regulator. 17. Remove fuel tube retainer bracket screw and fuel rail attaching bolts Fig. 10. Spread the retainer bracket to allow fuel tube removal clearance. Fig. 11 Fuel Injector Wiring Clip 18. Remove fuel rail injector wiring clip from the alternator bracket Fig. 11. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1989 19. Disconnect cam sensor, coolant temperature sensor, and engine temperature sensors Fig. 11. 20. Remove fuel injector wiring clip from intake manifold water tube. Fig. 12 Fuel Rail Removal 21. Remove fuel rail. Be careful not to damage the rubber injector O-rings upon removal from their port Fig. 12. Fig. 13 Intake Manifold Removal And Installation 22. Remove upper radiator hose, bypass hose and rear intake manifold hose Fig. 13. 23. Remove intake manifold bolts. Remove intake manifold. Fig. 14 Intake Manifold Gasket Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1990 24. Remove intake manifold seal retainers screws Fig. 14. Remove intake manifold gasket. INSPECTION Check for: ^ Damage and cracks of each section. ^ Clogged water passages in end crossovers. INSTALLATION 1. Clean all surfaces of cylinder block and cylinder heads. Fig. 15 Intake Manifold Gasket Sealing 2. Place a drop (approximately 1/4 in. diameter) of Mopar Silicone Rubber Adhesive Sealant or equivalent, onto each of the four manifold to cylinder head gasket corners Fig. 15. WARNING: Intake manifold gasket is made of very thin metal and may cause personal injury. Handle with care. 3. Carefully install the intake manifold gasket Fig. 14. Torque end seal retainer screws to 12 Nm (105 in.lbs.). 4. Install intake manifold and 8 bolts and torque to 1 Nm (10 in.lbs.). Then retorque bolts to 22 Nm (200 in.lbs.) in sequence shown in Fig. 13. Then retorque again to 22 Nm (200 in.lbs.). After intake manifold is in place, inspect to make sure seals are in place. 5. Make sure the injector holes are clean and all plugs have been removed. 6. Lube injector O-ring with a drop of clean engine oil to ease installation. 7. Put the tip of each injector into their ports. Push the assembly into place until the injectors are seated in the ports Fig. 12. 8. Install the 4 fuel rail attaching bolts and torque to 22 Nm (200 in.lbs.) Fig. 10. 9. Install fuel tube retaining bracket screw and torque to 4 Nm (35 in.lbs.) Fig. 10. 10. Reconnect cam sensor, coolant temperature sensor and engine temperature sensors Fig. 11. 11. Install fuel injector harness wiring clips on the alternator bracket and intake manifold water tube Fig. 11. 12. Connect fuel pressure regulator vacuum line. 13. Remove covering on lower intake manifold and clean surface. 14. Place intake manifold gasket on lower manifold. Put upper manifold into place and install bolts finger tight. 15. Install the alternator bracket to intake manifold bolt and the cylinder head to intake manifold strut bolts. (Do not torque). 16. Torque intake manifold bolts to 28 Nm (250 in.lbs.) following torque sequence in Fig. 9. 17. Torque alternator bracket to intake manifold bolt to 54 Nm (40 ft.lbs.) Fig. 8. 18. Torque the cylinder head to intake manifold strut bolts to 54 Nm (40 ft.lbs.) Fig. 5. 19. Connect ground strap, MAP and heated oxygen sensor electrical connectors Fig. 6. 20. Connect charge temperature sensor electrical connector Fig. 5. 21. Connect vacuum harness to intake plenum Fig. 5. 22. Using a new gasket, connect the EGR tube flange to the intake manifold and torque to 22 Nm (200 in.lbs.). 23. Clip wiring harness into the hole in the throttle cable bracket. 24. Connect the wiring connectors to the throttle position sensor (TPS) and Automatic Idle Speed (AIS) motor Fig. 4. 25. Connect vacuum harness to throttle body Fig. 4. 26. Install the direct ignition system (DIS) coils. Torque fasteners to 12 Nm (105 in.lbs.) Fig. 8. 27. Lubricate the ends of the chassis fuel tubes with 30 WT. oil. Connect fuel supply and return hoses to chassis fuel tube assembly. Pull back on the quick connect fitting to ensure complete insertion Fig. 7. 28. Install throttle cable Fig. 3. 29. Connect fuel injector wiring harness. 30. Install air cleaner and hose assembly Fig. 2. 31. Connect negative battery cable. Fill Cooling System. See Cooling System/Service and Repair. See: Cooling System/Service and Repair Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1991 32. With the DRB II use ASD Fuel System Test to pressurize system to check for leaks. CAUTION: When using the ASD Fuel System Test, The Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Testing and Inspection Crankshaft Main Bearing Seal: Testing and Inspection Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak. If the leakage occurs at the crankshaft rear oil seal area: 1. Disconnect the battery. 2. Raise the vehicle. 3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak. If a leak is present in this area remove transmission for further inspection. a. Circular spray pattern generally indicates seal leakage or crankshaft damage. b. Where leakage tends to run straight down, possible causes are a porous block, oil galley cup plug, bedplate to cylinder block mating surfaces and seal bore. See proper repair procedures for these items. 4. If no leaks are detected, pressurized the crankcase. CAUTION: Do not exceed 20.6 kPa (3 psi). 5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal. 6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled. 7. After the oil leak root cause and appropriate corrective action have been identified. Replace rear main seal. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Testing and Inspection > Page 2000 Crankshaft Main Bearing Seal: Service and Repair REMOVAL 1. Insert a 3/16 flat bladed pry tool between the dust lip and the metal case of the crankshaft seal. Angle the pry tool through the dust lip against metal case of the seal. Pry out seal. CAUTION: Do not permit the pry tool blade to contact crankshaft seal surface. Contact of the pry tool blade against crankshaft edge (chamfer) is permitted. INSTALLATION CAUTION: If burr or scratch is present on the crankshaft edge (chamfer), cleanup with 400 grit sand paper to prevent seal damage during installation of new seal. 1. Place Special Seal Pilot Tool C-4681, or equivalent on crankshaft. 2. Lightly coat seal O.D. with Loctite Stud N' Bearing Mount or equivalent. 3. Place seal over Special Seal Pilot Tool C-4, or equivalent and tap in place with a plastic hammer. REAR CRANKSHAFT SEAL RETAINER When retainer removal is required, remove retainer and clean engine block and retainer of old gasket. Make sure surfaces are clean and free of oil. Install new gasket and tighten screws to 12 Nm (105 inch lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Testing and Inspection > Page 2001 Rear Crankshaft Seal Pilot Tool C-4681 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Service and Repair > Cylinder Head Removal Cylinder Head Gasket: Service and Repair Cylinder Head Removal Fig. 6 Cylinder Head Assembly DESCRIPTION The aluminum alloy cylinder heads shown in Fig. 6 are held in place by 9 bolts. The spark plugs are located in peak of the wedge between the valves. REMOVAL 1. Drain cooling system and disconnect negative battery cable. Remove intake manifold, and throttle body. Refer to Engine/Intake Manifold/Service and Repair. See: Intake Manifold/Service and Repair 2. Disconnect coil wires, sending unit wire, heater hoses and by-pass hose. 3. Remove closed ventilation system, evaporation control system and cylinder head covers. 4. Remove exhaust manifolds. 5. Remove rocker arm and shaft assemblies. Remove push rods and identify to insure installation in original locations. Fig. 7 Cylinder Head Bolts Location 6. Remove the 9 head bolts from each cylinder head and remove cylinder heads Fig. 7. INSPECTION 1. Before cleaning, check for leaks, damage and cracks. 2. Clean cylinder head and oil passages. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Service and Repair > Cylinder Head Removal > Page 2006 Fig. 8 Check Cylinder Head 3. Check cylinder head for flatness Fig. 8. 4. Inspect all surfaces with a straightedge if there is any reason to suspect leakage. If out of flatness exceeds 0.019 mm (0.00075 inch). times the span length in inches in any direction, either replace head or lightly machine the head surface. As an example, if a 12 inch span is 1 mm (0.004 inch) out of flat, allowable is 12 x 0.019 mm (0.00075 inch) equals 0.22 mm (0.009 in.). This amount of out of flat is acceptable. NOTE: Maximum of 0.2 mm (0.008 inch) for grinding is permitted. CAUTION: This is a combined total dimension of stock removal from cylinder head and block top surface. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Service and Repair > Cylinder Head Removal > Page 2007 Cylinder Head Gasket: Service and Repair Cylinder Head Installation Fig. 29 Head Gasket Installation INSTALLATION 1. Clean all surfaces of cylinder block and cylinder heads. 2. Install new gaskets on cylinder block Fig. 29. Fig. 30 Checking Bolts For Stretching (Necking) 3. The cylinder head bolts are torqued using the torque yield method, they should be examined BEFORE reuse. If the threads are necked down, the bolts should be replaced Fig. 30. 4. Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt should be replaced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Service and Repair > Cylinder Head Removal > Page 2008 Fig. 31 Cylinder Head Tightening Sequence 5. Tighten the cylinder head bolts 1 through 8 in the sequence shown in Fig. 31. Using the 4 step torque turn method, tighten according to the following values: ^ First-All to 61 Nm (45 ft. lbs.) ^ Second-All to 88 Nm (65 ft. lbs.) ^ Third-All (again) to 88 Nm (65 ft. lbs.) ^ Fourth + 1/4 turn Do not use a torque wrench for this step NOTE: Bolt torque after 1/4 turn should be over 122 Nm (90 ft.lbs.). If not, replace the bolt. 6. Tighten head bolt number 9 Fig. 31 to 33 Nm (25 ft.lbs.) after head bolts 1 thorough 8 have been tighten to specifications. 7. Inspect push rods and replace worn or bent rods. Fig. 32 Rocker Arm Shaft Retainers 8. Install push rods, rocker arm and shaft assemblies with the stamped steel retainers in the four positions, tighten to 28 Nm (250 in.lbs.) Fig. 32. CAUTION: The rocker arm shaft should be torqued down slowly, starting with the center bolts. 9. Place new cylinder head cover gaskets in position and install cylinder head covers. Tighten to 12 Nm (105 in.lbs.). INTAKE MANIFOLD SEALING The intake manifold gasket is a one-piece stamped steel gasket with a sealer applied from the manufacturer. This gasket has end seals incorporated with it. WARNING: Intake manifold gasket is made of very thin metal and may cause personal injury. Handle with care. 1. Clean all surfaces of cylinder block and cylinder heads. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Service and Repair > Cylinder Head Removal > Page 2009 Fig. 33 Intake Manifold Gasket Sealing 2. Place a drop (about 1/4 in. diameter) of Mopar Silicone Rubber Adhesive Sealant or equivalent, onto each of the four manifold to cylinder head gasket corners Fig. 33. Fig. 34 Intake Manifold Gasket Retainers 3. Carefully install the intake manifold gasket Fig. 34. Torque end seal retainer screws to 12 Nm (105 in. lbs.). Fig. 35 Intake Manifold Removal And Installation 4. Install intake manifold and 8 bolts and torque to 1 Nm (10 in.lbs.). Then tighten bolts to 22 Nm (200 in.lbs.) in sequence shown in Fig. 35. Then tighten again to 22 Nm (200 in.lbs.). After intake manifold is in place, inspect to make sure seals are in place. Refer to Engine/Intake Manifold/Service and Repair to complete intake manifold assembly. See: Intake Manifold/Service and Repair 5. Install exhaust manifolds and tighten bolts to 27 Nm (20 ft. lb.) and nuts to 20 Nm (15 ft.lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Service and Repair > Cylinder Head Removal > Page 2010 6. Adjust spark plugs to specification and install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair REMOVAL 1. Raise vehicle on hoist. Remove right wheel and inner splash shield. 2. Remove drive belt. 3. Remove crankshaft damper. 4. Using Tool C-4991, or equivalent to remove oil seal. Be careful not to damage that crankshaft seal surface of cover. INSTALLATION 1. Install new seal by using Tool C-4992, or equivalent. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2014 2. Place seal into opening with seal spring towards the inside of engine. Install seal until flush with cover. 3. Install crankshaft pulley using plate L-4524, or equivalent. Thrust Bearing/washer and 5.9 inch screw. 4. Install drive belt. 5. Install inner splash shield and wheel. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2015 Front Crankshaft Seal Installer C-4992 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Specifications Intake Manifold Gasket: Specifications Gasket Retaining Screws .................................................................................................................... ................................................. 12 Nm (105 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Specifications > Page 2019 Intake Manifold Gasket: Service and Repair GENERAL INFORMATION The intake manifold gasket is a one-piece stamped steel gasket with a sealer applied from the manufacturer. This gasket has end seals incorporated with it. WARNING: INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND MAY CAUSE PERSONAL INJURY, HANDLE WITH CARE. INSTALLATION 1. Clean all surfaces of cylinder block and cylinder heads. 2. Place a drop (about 1/4 inch diameter) of Mopar Silicone Rubber Adhesive Sealant or equivalent, onto each of the four manifold to cylinder head gasket corners. 3. Carefully install the intake manifold gasket. Torque end seal retainer screws to 12 Nm (105 inch lbs.). 4. Install intake manifold and (8) bolts and torque to 1 Nm (10 inch lbs.). Then tighten bolts to 22 Nm (200 inch lbs.) in sequence shown. Then Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Specifications > Page 2020 tighten again to 22 Nm (200 inch lbs.). After intake manifold is in place, inspect to make sure seals are in place. 5. Install exhaust manifolds and tighten bolts to 27 Nm (20 ft. lbs.) and nuts to 20 Nm (15 ft. lbs.). 6. Adjust spark plugs to specification and install the plugs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Timing Cover Gasket > Component Information > Service and Repair Timing Cover Gasket: Service and Repair Timing Chain Cover Installation & Oil Seal Replacement 1. Ensure mating surfaces of chain case cover are clean and free of burrs. Crankshaft oil seal must be removed to ensure correct oil pump engagement. Fig. 18 Crankshaft Oil Seal Removal 2. Remove crankshaft oil seal using crankshaft removal tool No. C-4991, or equivalent, as shown in Fig. 18. Use caution not to damage crankshaft seal surface of cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Timing Cover Gasket > Component Information > Service and Repair > Page 2024 Fig. 19 Timing Case Cover Gasket & O-rings 3. Install a new cover gasket and new O-rings, Fig. 19. 4. Rotate crankshaft so oil pump drive flats are vertical. 5. Position oil pump inner rotor so mating flats are in same position as crankshaft drive flats, Fig. 19. 6. Install cover onto crankshaft. Ensure oil pump is correctly engaged on crankshaft or severe damage may result. 7. Install chain case cover screws and tighten to specifications. 8. Install crankshaft oil seal as follows: a. Position seal into opening with seal spring towards inside of engine. Fig. 20 Crankcase Oil Seal Installation b. Install seal until flush with cover using seal crankshaft seal installing tool No. C-4992, or equivalent, Fig. 20. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Timing Cover Gasket > Component Information > Service and Repair > Page 2025 Fig. 21 Crankshaft Pulley Installation 9. Install crankshaft pulley using thrust bearing/washer plate tool No. L-4524, or equivalent and a 5.9 inch screw, Fig. 21. Tighten crankshaft pulley bolt to specifications. 10. Install engine bracket, Fig. 14 and tighten attaching screws to specifications. 11. Install idler pulley on engine bracket. 12. Install cam sensor. 13. Install A/C compressor mounting bracket, then A/C compressor. 14. Install accessory drive belt. 15. Install right front inner splash shield, then wheel and tire assembly. 16. Install oil pump pickup, oil pan and transaxle inspection cover, if removed. 17. Install engine mount. 18. Fill crankcase with oil to proper level. 19. Fill cooling system. 20. Connect battery ground cable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Description and Operation Valve Guide Seal: Description and Operation Viton valve stem seals provide valve sealing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Description and Operation > Page 2029 Valve Guide Seal: Service and Repair 1. Perform fuel system pressure release procedure before attempting any repairs. 2. Disconnect negative battery cable. 3. Remove Air Cleaner Cover and hose assembly. 4. Remove upper Intake Manifold. 5. Remove cylinder head covers and spark plugs. 6. Remove connector wire from ignition coils. 7. Using suitable socket and flex handle at crankshaft pulley retaining screw, turn engine so the number 1 piston is at Top Dead Center on the compression stroke. 8. Remove rocker arms with rocker shaft and install a dummy shaft. The rocker arms should not be disturbed and left on shaft. 9. With air hose attached to spark plug adapter installed in number 1 spark plug hole, apply 90 to 100 psi air pressure (620.5 to 689 kPa). This is to hold valves into place while servicing components. 10. Using Tool C-4682, or equivalent compress valve spring and remove retainer valve locks and valve spring. 11. The intake valve stem seals should be pushed firmly and squarely over the valve guide using the valve stem as guide. Do Not Force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. CAUTION: Do not pinch seal between retainer and top of valve guide. 12. Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-2-3-4-5-6. Make sure piston in cylinder is at Top Dead Center (TDC) on the valve spring that is being covered. 13. Remove spark plug adapter tool. 14. Remove dummy shaft and install rocker shaft assembly and tighten screws to 28 Nm (250 inch lbs.). 15. Install cylinder head covers tighten screws to 14 Nm (120 inch lbs.) and connector to ignition coils. 16. Install Intake Manifold. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2036 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2037 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2038 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2039 Oil Pressure Sender: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2040 Engine Oil Pressure & Temp. System With Transmission Control Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt ....................................................................................................................... .................................................... 54 Nm (40 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Sprocket <--> [Crankshaft Gear/Sprocket] > Component Information > Description and Operation Crankshaft Sprocket: Description and Operation ACCESS PLUG An Access plug is located in the right inner fender shield. Remove the plug and insert the proper size socket, extension and ratchet, when crankshaft rotation is necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications Timing Chain: Specifications Number of Links .................................................................................................................................. .............................................................................. 64 Pitch ..................................................................................................................................................... ................................................................. 0.375 inch Width ................................................................................................................................................... .................................................................. 0.750 inch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Measuring Timing Chain Stretch Timing Chain: Service and Repair Measuring Timing Chain Stretch Fig. 16 Timing Chain Movement Inspection 1. Place a scale next to timing chain so chain movement can be measured. 2. Install a torque wrench and socket over camshaft sprocket, then apply torque in direction of crankshaft rotation to take up chain slack. Apply 30 ft. lbs. of torque with cylinder heads installed or 15 ft. lbs. of torque with cylinder heads removed. With torque applied to camshaft sprocket bolt, crankshaft should not move. It may be necessary to block crankshaft to prevent rotation. 3. Holding a scale with dimension reading even with edge of a chain link, apply specified torque in reverse direction and note amount of chain movement, Fig. 16. 4. If timing chain movement exceeds 1/8 inch, replace chain. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Measuring Timing Chain Stretch > Page 2053 Timing Chain: Service and Repair Timing Chain Replacement Removal TIMING COVER REMOVAL 1. Disconnect battery 2. Drain cooling system. Refer to Cooling System/Service and Repair for procedure. 3. Support engine and remove right engine mount. 4. Raise vehicle on hoist. Drain engine oil. 5. Remove oil pan and oil pump pick-up. It may be necessary to remove transmission inspection cover. 6. Remove right wheel and inner splash shield. 7. Remove drive belt. Refer to Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair for procedure. 8. Remove A/C compressor and set aside. 9. Remove A/C compressor mounting bracket. Fig. 43 Removing Crankshaft Pulley 10. Remove crankshaft pulley Fig. 43. 11. Remove idler pulley from engine bracket. Fig. 44 Engine Bracket (Typical) 12. Remove engine bracket Fig. 44. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Measuring Timing Chain Stretch > Page 2054 Fig. 45 Timing Chain Case Cover 13. Remove cam sensor from chain case cover Fig. 45. TIMING CHAIN REMOVAL 1. Remove camshaft sprocket attaching bolt, and remove timing chain with camshaft sprocket. 2. Using a suitable puller remove the crankshaft sprocket. Be careful not to damage the crankshaft surface. Installation TIMING CHAIN INSTALLATION 1. Position a new crankshaft sprocket on the shaft, install sprocket with suitable tool and mallet. Be sure sprocket is seated into position. 2. Rotate crankshaft so the timing arrow is to the 12 o'clock position. 3. Place timing chain around camshaft sprocket and place the timing mark to the 6 o'clock position. 4. Align the dark colored links with the dot on the camshaft sprocket, place timing chain around crankshaft sprocket with the dark colored link lined up with the dot on the sprocket and install camshaft sprocket into position. Fig. 49 Alignment Of Timing Marks 5. Using straight edge to check alignment of timing marks Fig. 49. 6. Install camshaft bolt and washer. Tighten to 54 Nm (40 ft. lbs.). 7. Rotate crankshaft 2 revolutions. Timing marks should line up. If timing marks do not line up remove cam sprocket and realign. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Measuring Timing Chain Stretch > Page 2055 Fig. 50 Camshaft Thrust Plate 8. Check camshaft endplay With new thrust plate the specification is 0.0127 to 0.304 mm (0.005 to 0.012 inches.). Old thrust plate specification is 0.31 mm (0.012 in.) maximum. If not within these limits install new thrust plate. TIMING COVER INSTALLATION 1. Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs. Crankshaft oil seal must be removed to insure correct oil pump engagement. NOTE: Do not use a sealer on cover gasket. Fig. 46 Timing Cover Rear Surface 2. Use a new cover gasket, O-rings Fig. 46. Adhere new gasket to timing cover, making sure that the lower edge of the gasket flush to 0.5 mm (0.020 in.) passed the lower edge of the cover. Refer to oil pan sealing outlined in this section. 3. Rotate crankshaft so that the oil pump drive flats are vertical. 4. Position oil pump inner rotor so the mating flats are in the same position as the crankshaft drive flats Fig. 46. 5. Install cover onto crankshaft. Make sure the oil pump is engaged on the crankshaft correctly or severe damage may result. 6. Install chain case cover screws and torque to 27 Nm (20 ft.lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Measuring Timing Chain Stretch > Page 2056 Fig. 47 Installation Of Crankshaft Front Oil Seal 7. Install crankshaft oil seal Fig. 47. Fig. 48 Installation Of Crankshaft Pulley 8. Install crankshaft pulley Fig. 48. 9. Install engine bracket Fig. 44 torque screws to 54 Nm (40 ft.lbs.). 10. Install idler pulley on engine bracket. 11. Install cam sensor. 12. Install A/C compressor mounting bracket. 13. Install A/C compressor. 14. Install drive belt. Refer to Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair for installation procedure. 15. Install inner splash shield and wheel. 16. Install oil pump pick-up and oil pan and transmission inspection cover if removed. 17. Install engine mount. 18. Fill crankcase with oil to proper level. 19. Fill cooling system. Refer to Cooling System/Service and Repair for procedure. 20. Connect battery Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Fundamentals and Basics > General Information Timing Chain: Fundamentals and Basics General Information TIMING CHAIN GENERAL INFORMATION PURPOSE The timing chain synchronizes (times) the opening and closing of the intake and exhaust valves with the movement/stroke of the pistons. OPERATION The crankshaft represents the movement of the pistons while the camshaft controls the opening and closing of the valves. The timing chain connects the crankshaft to the camshaft and uses the rotation of the crankshaft to drive the camshaft in a 2 to 1 relationship. For every two revolutions of the crankshaft the camshaft is rotated only once. WHY 2:1 In 4 stoke engine each piston must complete 4 separate strokes (intake, compression, power, and exhaust) to complete a cycle. For a single piston to complete all four strokes the crankshaft must rotate two full revolutions. The camshaft controls the opening and closing of the valves. During the four piston strokes of an engine cycle the intake and exhaust valves (for each cylinder) will open and close only once. This requires only one revolution of the camshaft. NOTE: The intake valves will open and close only during the intake stroke and the exhaust valves will open and close only during the exhaust stroke. During the compression and power strokes the valves remain closed. HOW This 2 to 1 reduction is accomplished by making the circumference of the camshaft twice as large as the crankshaft. This allows the smaller crankshaft to complete two revolutions while the larger camshaft completes only one revolution. FIRST INDICATIONS OF A BROKEN TIMING CHAIN - The engine will immediately die or fail to start. - When attempting to restart the engine, the cranking speed (rpm) will be unusually fast. - The sound of the engine while attempting to restart will be different than normal. Instead of the usual rhythmic "Rir. . .Rir. . .Rir cranking sound it will sound more like "RirRirRirRir" with no detectable rhythm. WHY When the timing chain brakes the camshaft quits rotating. Without the rotation of the camshaft the intake and exhaust valves stop opening and closing. This prevents the pistons from developing compression which also causes the engine to die. This lack of compression also produces the unusually fast and non-rhythmic cranking speed when attempting to restart the engine. NOTE: The normal rhythmic cranking sound is a result of the starter having to work harder as each piston begins its compression stroke. VERIFYING THE TIMING CHAIN IS BROKEN - Remove oil filler cap and check if the valve train or rocker arms are visible. If the timing chain is broken there will be no valve train movement while cranking the engine. - Perform a compression check. If the timing chain is broken no cylinder will develop compression. NOTE: Because this engine uses a distributorless ignition system and a crankshaft sensor the engine may still have ignition spark with a broken timing chain. OTHER RELATED PROBLEMS The Timing Chain has Jumped Teeth If the chain is excessively worn or missing teeth it is possible for the chain to jump teeth on the crankshaft. - A chain which is off by just one tooth will cause an engine to run very poorly or not run at all. - A chain which is off by more than one tooth will generally prevent the engine from starting. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Fundamentals and Basics > General Information > Page 2059 Timing Chain: Fundamentals and Basics Installation and Removal Hints and Tips TIMING CHAIN REPLACEMENT HINTS AND TIPS - Always replace both the timing chain and sprocket as a combined unit. A worn timing chain will not properly fit the teeth of a new sprocket and will result in a premature failure. - A new timing chain will rapidly wear away the teeth of an old sprocket. - Check ignition timing before (if possible) and after the procedure. This will help you verify the job was done properly. A timing chain which is off just one tooth will significantly alter the ignition timing. NOTE: Since the drive belt will need to be removed during this procedure, it is important to note any related deficiencies prior to starting the procedure. Inspect the water pump for signs of leakage and inspect the pulley for any looseness or wobble. If any wobble is detected the water pump should be replaced. - Inspect the drive belts and replace if necessary. - Inspect the drive belt idler/tensioner pulleys for looseness and wobble. Replace any pulley which does not spin freely or has any wobble. - Rotate the engine to number 1 Top Dead Center prior to removing the timing chain. - Oil pan removal is required to remove the timing cover. Bolts from the oil pan extend through the bottom of the timing cover. Removing the bolts and loosening the remaining pan bolts to remove the timing cover will tend to cause oil leakage from the pan gasket. NOTE: To prevent leakage, when the oil pan is removed or the bolts are loosened, the gasket should always be replaced. - When tightening the oil pan bolts always use a torque wrench. Correct sealing requires the gasket to be evenly torqued across its entire sealing surface. - Do not turn the crankshaft or camshaft with the pulleys off. Using slip joint pliers or pipe wrenches to turn the crankshaft will damage the surface and affect the press fit of the pulley. - Silicone sealant should be used very sparingly. Excessive sealant which squeezes out on the inside of the gasket can accumulate and restrict the oil pump pickup screen or the coolant heater core. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications M8x1.25 Bolts ...................................................................................................................................... .................................................... 27 Nm (20 ft. lbs.) M10x1.5 Bolts ................................................... ....................................................................................................................................... 54 Nm (40 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2063 Timing Cover: Service and Repair Fig. 6 Crankshaft pulley removal Fig. 7 Engine bracket Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2064 Fig. 8 Timing case cover REMOVAL 1. Disconnect battery ground cable. 2. Drain cooling system. 3. Support engine, then remove right engine mount. 4. Raise and support vehicle, then drain engine oil. 5. Remove oil pan and oil pump pick up. It may be necessary to remove transaxle inspection cover. 6. Remove accessory drive belt as follows: a. Remove right front wheel and tire assembly, then the inner splash shield. b. Release belt tension by rotating tensioner clockwise, then remove accessory drive belt. 7. Remove A/C compressor and position aside. 8. Remove A/C compressor mounting bracket. 9. Using a suitable puller, remove crankshaft pulley as shown, Fig. 6. Pull from inner hub area only. 10. Remove idler pulley from engine bracket, then the engine bracket, Fig. 7. 11. Remove cam sensor from chain case cover, then the chain case cover, Fig. 8. REPLACEMENT 1. Ensure mating surfaces of chain case cover are clean and free of burrs. Crankshaft oil seal must be removed to ensure correct oil pump engagement. Fig. 11 Crankshaft oil seal removal 2. Remove crankshaft oil seal using crankshaft removal tool No. C-4991 or equivalent, as shown in Fig. 11. Use caution not to damage crankshaft seal surface of cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2065 Fig. 12 Timing case cover gasket & O-rings 3. Install a new cover gasket and new O-rings, Fig. 12. 4. Rotate crankshaft so oil pump drive flats are vertical. 5. Position oil pump inner rotor so mating flats are in same position as crankshaft drive flats, Fig. 12. 6. Install cover onto crankshaft. Ensure oil pump is correctly engaged on crankshaft or severe damage may result. 7. Install chain case cover screws and tighten to specifications. 8. Install crankshaft oil seal as follows: a. Position seal into opening with seal spring towards inside of engine. Fig. 13 Crankcase oil seal installation b. Install seal until flush with cover using seal crankshaft seal installing tool No. C-4992 or equivalent, Fig. 13. Fig. 14 Crankshaft pulley installation 9. Install crankshaft pulley using thrust bearing/washer plate tool No. L-4524 or equivalent and a 5.9 inch screw, Fig. 14. Tighten crankshaft pulley bolt to specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2066 Fig. 7 Engine bracket 10. Install engine bracket, Fig. 7 and tighten attaching screws to specifications. 11. Install idler pulley on engine bracket. 12. Install cam sensor. 13. Install A/C compressor mounting bracket, then the A/C compressor. 14. Install accessory drive belt. 15. Install right front inner splash shield, then the wheel and tire assembly. 16. Install oil pump pickup, oil pan and transaxle inspection cover, if removed. 17. Install engine mount. 18. Fill crankcase with oil to proper level. 19. Fill cooling system. 20. Connect battery ground cable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations Fig 1 Intake Plenum Mounting Bolts Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications Air/Fuel Mixture: Specifications The Air/Fuel Ratio is controlled by the Powertrain Control Module (PCM) and is not adjustable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications > Page 2075 Air/Fuel Mixture: Adjustments CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle mixture using this screw! Idle mixture is electronically controlled by the Powertrain Control Module (PCM), and is not adjustable. If an idle mixture problem is suspected, check oxygen sensor and feedback system. SEE Computers and Control Systems. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications NOTE: Idle speed is not adjustable. Powertrain Control Module (PCM) controls idle speed through Idle Air Control (IAC) Motor. If idle speed is outside of specifications, or is rough, or unstable, inspect and clean throttle body, (if deposits are visible). After cleaning throttle body perform minimum air flow test. SEE DIAGNOSIS, TESTING AND INSPECTION PROCEDURES MINIMUM AIRFLOW TEST IDLE SPEED ODOMETER READING IDLE SPEED Less than 1000 miles 525-875 RPM More than 1000 miles 575-875 RPM Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2079 Idle Speed: Adjustments CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle speed using this screw, unless directed to do so in a service procedure. Idle speed is electronically controlled by the Powertrain Control Module (PCM) through the Idle Air Control (IAC) motor, and is not adjustable. If idle is outside of specified RPM, or is rough, or unstable, inspect and clean throttle body if deposits are visible. Perform Minimum Idle Air Flow Test if applicable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fig 1 Intake Plenum Mounting Bolts Fuel Pressure Release Procedure - Typical WARNING: The fuel system is under constant pressure of approximately 48 psi (330 kPa), even when the engine is OFF. 1. Disconnect negative battery cable. 2. Loosen fuel tank filler cap to relieve fuel tank pressure. 3. Remove cap on fuel rail pressure test port (Fig. 1). 4. Place one end of fuel pressure release hose, tool C-4799-1 (or equivalent), in an approved gasoline container. Connect the other end of this hose to the fuel rail service port. Fuel pressure should bleed off into container. 5. Perform necessary fuel system service procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications 3.3L, 3.8L Except Code T Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations 3.3L, 3.8L Except Code T Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations This vehicle is not equipped with timing marks. However spark advance can be monitored using a DRBII or equivalent scan tool. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Ignition Cable: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 2102 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 2103 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Ignition Cable: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 2109 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 2110 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2111 Ignition Cable: Specifications Minimum ..................................................................................................................................................... 250 ohms per inch (3,000 ohms per foot) Maximum ............................................................................................................................................... 1,000 ohms per inch (12,000 ohms per foot) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2112 Ignition Cable: Description and Operation NOTE: Spark Plug cables are sometimes referred to as "secondary ignition wires". Purpose Transfer electrical current from the distributor to individual spark plugs at each cylinder. Resistance type cables are used to suppress Radio Frequency Interference (RFI), from the ignition system. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Ignition Cable: Initial Inspection and Diagnostic Overview INSPECTION Check the high-tension cable connections for good contact at the ignition coil, distributor cap towers and spark plugs. Terminals should be fully seated. The terminals and covers should be in good condition. Terminals should fit tightly to the ignition coil, distributor cap, and spark plugs. The cover (boot) of the cable should fit tight at the coil tower, distributor tower or spark plug insulator. NOTE: Loose cable connections can cause corrosion and increase resistance resulting in shorter cable service life. To maintain proper sealing at terminal connections, do not disconnect cables. This should only be done when testing. Clean high tension cables with a cloth moistened with a nonflammable solvent and wipe dry. Check for brittle or cracked insulation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2115 Ignition Cable: Component Tests and General Diagnostics Secondary Ignition Cable Insulation Test CAUTION: Do not pull spark plug cables from distributor cap of four cylinder engines. The cables must be released from inside the distributor cap. CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during testing. Excessive heat could damage the catalytic converter. Total test time must not exceed ten minutes. CAUTION: To maintain proper sealing at the terminal connections, the connections should not be broken unless testing indicates high resistance, an open circuit or other damage. INSPECTION Check connections at the coil, distributor cap towers and spark plugs. Terminals should be fully seated, and the nipples and spark plug covers should be in good condition. Covers should fit tightly on the coil, distributor cap towers and spark plug insulators. Cable connections that are loose will corrode and increase the resistance and permit water to enter the towers causing ignition malfunction. INSULATION TEST NOTE: When testing secondary cables for punctures and cracks with an oscilloscope follow the equipment manufacturers instructions. If an oscilloscope is not available, secondary cables can be tested as follows: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. 2. With engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. Check the coil cable the same way. 3. Replace ALL cracked, leaking or faulty cables. RESISTANCE TEST Use an ohmmeter to check resistance type cable for open circuits, loose terminals or high resistance as follows: Remove cable from spark plug. Lift distributor cap from distributor with cables intact. Do not remove cables from cap. The cables must be removed from the spark plugs. Connect the ohmmeter between spark plug end terminal and the corresponding electrode inside the cap, make sure ohmmeter probes arc in good contact. Resistance should be within tolerance shown in the cable resistance chart. If resistance is not within tolerance, remove cable at cap tower and check the cable. If resistance is still not within tolerance, replace cable assembly. Test all spark plug cables in same manner. To test coil to distributor cap high tension cable, remove distributor cap with the cable intact. Do not remove cable from the cap. Connect the ohmmeter between center contact in the cap and remove the cable at coil tower and check cable resistance. If resistance is not within tolerance, replace the cable. Also, check for a loose connection at the tower or for a faulty coil. Inspect coil tower for cracks or carbon tracking. Secondary Ignition Cable Resistance Test CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during testing. Excessive heat could damage the catalytic converter. Total test time must not exceed ten minutes. CAUTION: To maintain proper sealing at the terminal connections, the connections should not be broken unless testing indicates high resistance, an open circuit or other damage. NOTE: Use an ohmmeter to check resistance type cable for open circuits, loose terminals or high resistance as follows: SPARK PLUG CABLES 1. Remove cable from spark plug. 2. Lift distributor cap from distributor with cables intact. Do not remove cables from cap. The cables must be removed from the spark plugs. 3. Connect the ohmmeter between spark plug end terminal and the corresponding electrode inside the cap, ensure probes make good contact. Resistance should be within tolerance. 4. If the resistance is not within tolerance, remove cable at cap tower and check the cable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2116 5. If resistance is still not within tolerance, replace cable assembly. 6. Test all spark plug cables in same manner. COIL TO DISTRIBUTOR HIGH TENSION CABLE 1. Remove distributor cap with the cable intact. Do not remove cable from the cap. 2. Remove the cable at coil tower 3. Connect the ohmmeter between center contact in the cap and the coil end of cable. 4. If resistance is not within tolerance, replace the cable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications Spark Plug: Specifications Gap Specifications NOTE: Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Spark Plug Gap ................................................................................................................................... ............................... 1.2 to 1.3 mm (0.048 to 0.053 in) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications > Page 2121 Spark Plug: Specifications Tightening Specifications Spark Plug Torque ............................................................................................................................... ....................................................... 28 Nm (20 ft-lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2122 Spark Plug: Description and Operation Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for spark plug diagnosis. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator NOTE: Replace any spark plugs which have cracked broken or chipped insulators. Symptoms: Insulator chipped or broken. Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap. - Severe detonation also can separate the insulator from the center electrode. - Sudden Rise In Tip Temperature. - Severe Operating Conditions. - Improper Gapping Of Plugs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2125 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2126 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Symptoms: Dry, black deposits on the electrodes. Possible Causes: - On one or two plugs, may be caused by sticking valves or defective spark plug cables. - On the entire set, may be caused by a clogged air cleaner. - Poor Ignition Output NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs do not reach a high enough operating temperature during short operating periods to burn fuel completely. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2127 Spark Plug: Testing and Inspection Electrode Gap Bridging Electrode Gap Bridging Symptoms: Gap between the electrodes bridged by deposits. Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the electrodes. NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2128 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator NOTE: Replace any spark plugs which have cracked broken or chipped insulators. Symptoms: Insulator chipped or broken. Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap. - Severe detonation also can separate the insulator from the center electrode. - Sudden Rise In Tip Temperature. - Severe Operating Conditions. - Improper Gapping Of Plugs. Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Symptoms: Dry, black deposits on the electrodes. Possible Causes: - On one or two plugs, may be caused by sticking valves or defective spark plug cables. - On the entire set, may be caused by a clogged air cleaner. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2129 - Poor Ignition Output NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs do not reach a high enough operating temperature during short operating periods to burn fuel completely. Electrode Gap Bridging Electrode Gap Bridging Symptoms: Gap between the electrodes bridged by deposits. Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the electrodes. NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures. Heavy Colored Deposits DESCRIPTION: Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on the side facing the intake valve. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap, and reinstall .............................................................................................................................................................. .................................................................................... Oil or Ash Encrusted Oil Or Ash Encrusted Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2130 Symptoms: Electrodes encrusted with dry oil or ash. Possible Causes: One or more plugs, evaluate the cause of oil entry into the combustion chamber. Premature Electrode Wear - Preignition Damage Preignition Damage Symptoms: Center electrode dissolves first and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Possible Causes: Excessive combustion chamber temperature. - Incorrect spark plug heat range [1]. - Ignition timing is over advanced - Other operating conditions are causing engine overheating. [1] Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Red, Brown, Yellow or White Deposits - Fuel Additives Scavenger Deposits Symptoms: Red, Brown, White or Yellow deposits. Possible Causes: Normal condition caused by certain fuel additives which are designed to change the nature of deposits and decrease spark plug misfire tendencies. NOTE: Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and be cleaned using standard procedures. Shiny Yellow Glaze DESCRIPTION: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2131 Shiny yellow glaze coating on the insulator. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Metal By-products Of Combustion - Avoid sudden acceleration with wide open throttle after long periods of low speed driving. .............................................................................................................................................................. .................................................................................... Spark Plug Inspection PROCEDURE - Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance Schedules. - Spark plugs that have low mileage may be cleaned and reused if not otherwise defective. Refer to the Spark Plug Condition of this section. After cleaning, file the center electrode flat with a small point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The spark plug gap is 0.89 mm (0.035 in). - Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Spark Plug Resistance Test Resistance should be at least 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Wet Oily Deposits Symptoms: Electrodes coated with excessive wet fuel or oil. Possible Causes: In older engines, wet fouling can be caused by worn rings or excessive cylinder wear. - In new or recently overhauled engines, fouling may occur before normal oil control is achieved. Break-in fouled spark plugs can be usually be cleaned and installed. White or Gray - Burned or Blistered Insulator Spark Plug Overheating Symptoms: White or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in per 1000 miles of operation. Possible Causes: Plug(s) with wrong heat range. - Over advanced ignition timing. - Detonation - Cooling system malfunction - Check for lean air-fuel mixture - Check the torque value of the plugs to ensure good plug-engine seat contact Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2132 Spark Plug: Adjustments Setting Spark Plug Electrode Gap Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground -- center electrode. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Replacement Notes Spark Plug: Service and Repair Replacement Notes TIP: Always keep plugs in the order they were removed. Any plug that looks different from other plugs indicates a problem in that cylinder. NOTE: For further diagnosis by spark plug condition SEE Ignition System/Spark Plug/Testing and Inspection/Procedures Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Replacement Notes > Page 2135 Spark Plug: Service and Repair Removal and Installation CAUTION: Note routing of secondary ignition cables before removing. Failure to route cables properly may result in radio interference, ignition cross fire, or ignition short to ground. NOTE: Keep plugs in order removed. A plug, that looks different from the rest, could be a problem indicator. REMOVAL 1. Spray compressed air around spark plug to prevent foreign material from entering combustion chamber. 2. Remove spark plug wire by grasping boot and turning 1/2 turn while pulling boot back in a steady motion. 3. Remove spark plug using socket with foam insert. INSPECT FOR: - Color of Deposits - Excessive Deposits - Electrode wear - Cracked or Damaged Threads Or Insulator - Worn or Bent Electrodes - Damaged Gasket INSTALLATION 1. Start plug in cylinder head by hand, to prevent cross threading. CAUTION: Do not overtighten plugs, overtightening can distort plugs resulting in a changed gap. 2. Torque spark plugs to 20 ft-lbs (28 Nm). 3. Install secondary ignition cables on spark plugs, (be sure connectors are pushed onto plug completely). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Cylinder Compression Pressure 100 psi NOTE: No more than 25% variance between cylinders. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2139 Compression Check: Service Precautions COMPRESSION TESTING When performing a compression test, remove the fuel pump relay fuse and disconnect power to the ignition. This will stop fuel flow to the injectors and prevent engine from starting. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2140 Compression Check: Testing and Inspection PROCEDURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire (Conventional Ignition System). For Direct Ignition System (DIS) disconnect the coil connector. 5 . Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adaptor into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is reached on gage. Record this pressure as #1 cylinder pressure. 7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 9. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. 11. Clean or replace spark plugs as necessary and adjust gap. Tighten to specifications. 12. Test resistance of spark plug cables. Perform secondary circuit inspection. 13. Test coil output voltage, primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at idle and different RPM ranges. 15. The air filter elements should be replaced as specified. 16. Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt drives. 18. Road test vehicle as a final test. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments This engine uses hydraulic lash adjusters, no adjustment is necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and Inspection > Verifying Water Pump Problem Water Pump: Testing and Inspection Verifying Water Pump Problem VERIFYING WATER PUMP PROBLEM Check for Loose Water Pump Pulley As the pump shaft seals and bearings wear with age the pulley/shaft may develop a wobble or lateral runout. With the engine off and the key removed from the ignition, attempt to move the pulley from side to side and back and forth. There should be no detectable movement. The pulley should turn smoothly, with no rough spots. The water pump should be replaced if any pulley wobble is detected. If the water pump is not replaced the pump shaft may eventually seize or break. NOTE: Incorrect belt tension (too tight) may cause premature wear of the bearings and seals. WARNING: Never remove a radiator cap while the engine is hot. Severe personal injury may result. Inspect for Leakage 1. With the engine "OFF" and cold: - Check coolant level and refill if necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and Inspection > Verifying Water Pump Problem > Page 2148 - Inspect the water pump for leakage. Closely check the following areas: Inspection (weep) hole. - Pump shaft. - Gasket. 2. Pressurize the cooling system with a pressure tester and again check for leaks. Do not exceed the rated pressure of the radiator cap. NOTE: If any leaks are found, verify that they are not originating from a component near or above the water pump (i.e. thermostat, loose radiator hoses, intake gasket, engine coolant temperature sensor) CAUTION: When finished, immediately re-install the radiator cap. 3. If no leaks are found, start and warm the engine until the thermostat opens. Stop the engine and check for fresh leakage around the water pump shaft. NOTE: Occasionally water pumps will only leak around the shaft seals while the shaft is rotating. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and Inspection > Verifying Water Pump Problem > Page 2149 Water Pump: Testing and Inspection After Repairs Operational Check COOLING SYSTEM OPERATIONAL CHECK IMPORTANT: Always verify the operation of the thermostat and cooling fan prior to driving the vehicle after a cooling system repair. HOW - With the cooling system filled with coolant and the radiator cap installed, start the engine and allow the coolant to warm up. - The upper radiator hose should remain cool to the touch until the coolant within the engine block and head has reached the thermostat opening temperature. The thermostat opening should be indicated by a rapid warm up of the upper radiator hose. - If upper hose gradually warms up, the thermostat may be stuck open (assuming the engine is started cold) - If the coolant temperature reaches the normal operating temperature (as indicated by the temperature gauge) before the upper hose becomes warm, the engine should be turned off, and the cooling system allowed to cool down. The thermostat may be stuck closed and should be removed and tested. WARNING: Never remove the radiator cap, or disconnect a coolant hose on a warm engine. A warm cooling system may contain a large amount of stored energy in the form of steam and high pressure, which could seriously injure you. - If the thermostat opened properly, continue to allow the cooling system to warm up. As the coolant temperature reaches its maximum operating temperature the electrical cooling fan should energize. Verify the fan energizes and de-energizes. WHY Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and Inspection > Verifying Water Pump Problem > Page 2150 Thermostat Closed, Cold Engine - With the thermostat closed, coolant flow through the radiator is blocked forcing the coolant to re-circulate through the block and head. This allows for a rapid warm up. During this time there should be little or no coolant flow through the upper radiator hose. Thermostat Open, Warm Engine - Once the coolant has reached normal operating temperature, the thermostat begins to open, allowing coolant flow through the upper hose and into the radiator. The thermostat will continue to regulate the amount of coolant flow to the radiator to maintain a "Minimum" operating temperature. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and Inspection > Verifying Water Pump Problem > Page 2151 Water Pump: Testing and Inspection After Repairs Leak Check AFTER REPAIRS LEAK CHECK PURPOSE Initially fill the cooling system and check for leaks prior to starting the engine and bleeding the system. Although the system will not be completely full, any leaks which are detected may be fixed before the engine and cooling system are hot. NOTE: It is much easier to repair a leak on a cold engine than on a hot engine. HOW - Fill the cooling system until the radiator is full. - Apply pressure to the system with a pressure tester. - Carefully check for leaks around: All hoses and clamps. - Water pump sealing surfaces. - Any cooling system component which was removed or replaced. - If no leaks are detected continue with the fill and bleed procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Removal Water Pump: Service and Repair Removal Fig. 6 Water Pump REMOVE 1. Drain Cooling System. 2. Remove Accessory Drive Belt. 3. Remove right front lower fender shield. 4. Remove pump pulley bolts and remove pulley. 5. Remove pump mounting screws Remove pump. Fig. 7 Water Pump Body 6. Remove and discard O-ring seal. 7. Clean O-ring groove and O-ring surfaces on pump and chain case cover. Take care not to scratch or gouge sealing surface. INSPECT NOTE: Replace the water pump if it has any of the following defects. 1. Damage or cracks on the pump body. 2. Coolant leaks; if the seal is leaking, evident by traces of coolant leaks from vent hole. 3. Loose or rough turning bearing. 4. Impeller - rubs either the pump body or chain case cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Removal > Page 2154 Water Pump: Service and Repair Installation Fig. 7 Water Pump Body Fig. 6 Water Pump INSTALL 1. Install new O-ring in O-ring groove. 2. Install pump to chain case cover. Torque screws to 12 Nm (105 in.lbs.). 3. Rotate pump by hand to check for freedom of movement. 4. Position pulley on pump. Install screws and torque to 30 Nm (250 in.lbs.). 5. Install drive belt. See Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair. See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair 6. Install right front lower fender shield. 7. Refill Cooling System. See Cooling System/Service and Repair. See: Cooling System/Service and Repair Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Page 2155 Water Pump: Tools and Equipment RECOMMENDED TOOLS - Drip pan - For draining coolant. - Torque Wrenches (0-30 in lbs). - Full set of Metric sockets and wrenches. - Fender covers. OPTIONAL - Radiator hose removal tool. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Page 2156 - Cooling system pressure tester. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations Water Pump: Fundamentals and Basics Initial Preparations INITIAL PREPARATIONS Disconnect Battery When working near or around the cooling fan or drive belts, accidentally engaging the starter or cooling fan can result in serious personal injury. The negative battery terminal should be disconnected prior to commencing work and should not be reconnected until after the water pump is installed and the engine is ready to restart. Fender Covers Fender covers will prevent damage to the vehicles finish while performing the job. NOTE: A fender cover folded over the radiator will prevent accidental damage to the radiator. The radiator can be easily damaged should a wrench slip off of a bolt while working on the water pump. Coolant Drip Pan Pre-position a drip pan under the vehicle to prevent any incidental spills. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 2159 Water Pump: Fundamentals and Basics Removal Tips and Hints WATER PUMP REMOVAL NOTES, WARNINGS, AND HINTS FROZEN AND BROKEN BOLTS Frozen and broken bolts are often a major problem when removing water pumps. Coolant can seep into the bolt holes resulting in corrosion and frozen bolts. Prior to starting the job, spray all water pump retaining bolts with a penetrating oil. Upon removal, any bolt or nut which shows signs of corrosion should be replaced. The threads of the associated bolt hole should be re-tapped or chased. Inspect the coolant hoses, drive belts, and associated pulleys. Since these components will need to be removed to replace the timing belt it would be convenient/time saving to have any necessary replacement parts on hand prior to removing the pump. COOLANT HOSES Inspect the hoses for the following: Cracks, especially near the hose clamps. - Swelling, look for areas of the hose that appear unnaturally bulged outwards. NOTE: This is often caused by improper removal techniques, see Hose Removal in this article. - Oil contamination and soft spots. Oil contamination breaks down the structure of the rubber and significantly weakens the hose. NOTE: The oil leak should be fixed prior to replacing the hose. - Hard or brittle hoses, as the hoses age the rubber looses its resiliency and becomes brittle. The hoses need to be able to flex to compensate for the movement of the engine. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 2160 DRIVE BELTS Small cracks that run across that run across the ribbed surface of the belt from rib to rib , are considered normal, These are not reasons to replace the belt. If chunks of belt material are missing between the cracks, the belt should be replaced. Cracks running along the rib (not across) are not normal. Any belts with cracks running along the rib should be replaced. Replace the belt if it has excessive wear, frayed cords or severe glazing. Drive Pulleys - Verify the pulleys have no side to side wobble, and rotate freely. Replace if necessary. - Verify the pulleys are properly aligned. Adjust or replace as necessary. Belt Removal Do not attempt to bump the drive belts off with the starter. This practice can damage the belt, pulley, and technician. Removing the belt by relaxing the tension will allow you to correctly adjust the tension when installing the belt. DRIP PAN Prior to removing any hose or the water pump, place a large drip pan under the engine. Although the coolant may be drained from the radiator, there is still a large amount of residual coolant trapped in the hoses and water pump. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 2161 HOSE REMOVAL Prior to pulling the hose from the fitting, rotate/twist the hose on the fitting to break the grip of any corrosion present. If the hose is to be replaced, it may be quicker to cut hose from the fitting. CAUTION: When cutting the hose be careful not to damage the fitting. A radiator hose removal tool may help free up stubborn hoses. CAUTION: Do not use any device to pry the hose off of the fitting. - If at any time a tearing or ripping sound is heard (though the hose appears fine) the hose should be replaced. The sound is coming from the internal reinforcing fibers embedded in the hose. Once the fibers have been broken the hose will be subject to swelling and rupture when pressure is applied. WATER PUMP REMOVAL After removing the retaining bolts the water pump may still be stuck to the engine. The original gasket sealant may cause the pump to firmly stick to engine. A few soft blows from a rubber mallet or block of wood will generally loosen the pump. CAUTION: Verify that ALL of the retaining bolts are removed. - Do not pry between the pump and the gasket. This may damage the pump sealing surface. - Upon breaking the seal, a large amount of coolant trapped in the block will generally pour out from the water pump opening. Be sure to have a drip pan prepositioned. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 2162 Water Pump: Fundamentals and Basics Installation Tips and Hints WATER PUMP INSTALLATION NOTES - Compare the old pump to the new pump and verify: Shaft lengths match exactly. - Retaining bolt holes match exactly. - Verify the retaining bolts and bolt holes have clean threads. Re-tap or chase the threads as necessary. - Do not over tighten the retaining bolts, use a torque wrench to properly tighten the bolts to the correct specification. CAUTION: Water pump retaining bolts may be easily broken or stripped, do not tighten the retaining bolts with an air wrench or impact gun. - When tightening hose clamps: Position the hose squarely on the fitting. - Verify the hose clamp is clear of the retaining rim on the fitting. Do not over tighten the clamps. - While working on the cooling system it is a good habit to clean the radiator and A/C condenser fins of bugs and dirt. This build up of debris can seriously reduce the cooling ability of the system. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 2163 Water Pump: Fundamentals and Basics Recommended Parts RECOMMENDED PARTS - New water pump O-ring. - Engine Coolant: NOTE: For optimum performance, use 50/50 mixture of high quality ethylene glycol coolant and water. OPTIONAL, PENDING INSPECTION - Radiator hoses. - Drive belt. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations Coolant: Technical Service Bulletins Engine - Coolant Recommendations NO: 07-03-97 GROUP: Cooling DATE: May 9, 1997 SUBJECT: Engine Coolant Usage THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-05-93 DATED NOV. 26, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1993 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-94000). THE COMPLETE BULLETIN IS REVISED. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1997 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger/ Power Ram/Power Ram Cab & Chassis 1989 - 1993 (AG) Daytona 1989 (AH) Lancer/LeBaron GTS 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1997 (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1997 (BR) Ram Truck 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1989 - 1992 (MJ) Comanche 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1997 (PR) Prowler 1992 - 1997 (SR) Viper/Viper Coupe 1997 (TJ) Wrangler 1989 - 1997 (XJ) Cherokee 1989 - 1995 (YJ) Wrangler 1993 - 1997 (ZJ) Grand Cherokee DISCUSSION: Some owners have expressed interest in using engine coolants made with propylene glycol instead of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals. Based on recent test data, most owners should not experience significant effects on cooling system performance when using propylene glycol based coolant. The use of national brand propylene glycol based engine coolant that meets the same Chrysler ethylene glycol specification of MS-7170 (or equivalent ASTM D5216) is acceptable for Chrysler built vehicles. NOTE: ANTIFREEZE SOLD FOR PROTECTING PLUMBING ETC. (RV ANTIFREEZE) IS NOT A SUITABLE ENGINE COOLANT. However, owners should be discouraged from changing their engine coolant prior to the regularly scheduled maintenance period. Prematurely changing engine coolant unnecessarily adds to the risk of environmental exposure. Sufficient freeze protection for the region should be maintained. However, do not use more than a 55% solution (-35 F, -37 C). Use the chart that accompanies the propylene glycol coolant, since a higher concentration is required to obtain the same freeze points as ethylene glycol coolant. If the temperatures for your region fall below this, use ethylene glycol coolant. Under severe driving conditions (towing a trailer in hot weather etc.) there may be a slight loss in cooling performance. If this is noticed, the system should be changed back to ethylene glycol coolant. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations > Page 2169 The two types of coolant should not be mixed. The standard testers for measuring freeze protection will not provide an accurate reading when this occurs. If the cooling system is changed to propylene glycol, all the ethylene glycol coolant should be removed using an approved cooling system flush procedure. The freeze protection of propylene glycol cannot be measured with a standard cooling system hydrometer. A refractometer or hydrometer calibrated for propylene glycol is the preferred test tool. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Page 2170 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Motor: > 07-06-98 > Nov > 98 > Cooling Module Fan - Vibrates/Comes Loose Radiator Cooling Fan Motor: Customer Interest Cooling Module Fan - Vibrates/Comes Loose NO: 07-06-98 GROUP: Cooling DATE: Nov. 20, 1998 SUBJECT: Cooling Module Fan Nut MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (International Market) DISCUSSION: Some subject vehicles may experience a loosening or loss of the nut retaining the engine cooling module fan causing a vibration initially. If not addressed promptly, the fan blade will not turn and the engine may overheat. A revised engine cooling module fan retaining nut kit has been released, p/n 05011946AA, to address this condition and should be used for repair any time this condition is experienced and the fan blade is not damaged. The cooling fan blade and motor were balanced as an assembly at the time of manufacture and must be properly oriented to minimize vibration. The cooling fan blade can be installed on the cooling motor shaft in one of two positions. If the cooling fan blade/motor assembly vibrates excessively after replacing the nut, remove and reinstall the cooling fan blade on the motor shaft 180 degrees from the first installation position. The proper torque for the revised fan retaining nut is 6.3-7.3 Nm (55-65 in. lbs.). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor: > 07-06-98 > Nov > 98 > Cooling Module Fan - Vibrates/Comes Loose Radiator Cooling Fan Motor: All Technical Service Bulletins Cooling Module Fan - Vibrates/Comes Loose NO: 07-06-98 GROUP: Cooling DATE: Nov. 20, 1998 SUBJECT: Cooling Module Fan Nut MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (International Market) DISCUSSION: Some subject vehicles may experience a loosening or loss of the nut retaining the engine cooling module fan causing a vibration initially. If not addressed promptly, the fan blade will not turn and the engine may overheat. A revised engine cooling module fan retaining nut kit has been released, p/n 05011946AA, to address this condition and should be used for repair any time this condition is experienced and the fan blade is not damaged. The cooling fan blade and motor were balanced as an assembly at the time of manufacture and must be properly oriented to minimize vibration. The cooling fan blade can be installed on the cooling motor shaft in one of two positions. If the cooling fan blade/motor assembly vibrates excessively after replacing the nut, remove and reinstall the cooling fan blade on the motor shaft 180 degrees from the first installation position. The proper torque for the revised fan retaining nut is 6.3-7.3 Nm (55-65 in. lbs.). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2187 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2188 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2189 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2190 Radiator Cooling Fan Motor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2191 Radiator Cooling Fan Motor: Electrical Diagrams Air Conditioning System (Part 1 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2192 Air Conditioning System (Part 2 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2193 Air Conditioning System (Part 3 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2194 Air Conditioning System (Part 4 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2195 Radiator Fan System With Heater Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2196 Heater System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2197 Radiator Cooling Fan Motor: Description and Operation Fig. 1 Electric Cooling Fan Module Fig. 2 Electric Cooling Fan Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2198 Fig. 3 Electric Cooling Fan Module ELECTRIC COOLING FANS, DESCRIPTION The electric cooling fan, is controlled by a fan switch which is located on the radiator or engine, or is activated by an on-board computer. The switch on the radiator will engage the fan when coolant temperature reaches 200°F. The on-board computer uses two thermistor sensors, one of which is for the cooling system fan, to detect coolant temperature. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2199 Radiator Cooling Fan Motor: Testing and Inspection ELECTRIC FAN MOTOR 1. Disconnect fan motor electrical connector. 2. Connect jumper wire to positive side of fan motor connector. 3. Fan should operate properly; if not, replace fan motor. 4. If fan is noticeably overheated, system voltage may be too high. Inspect charging system as necessary. Refer to Cooling System / Testing and Inspection / Procedures / Diagnostic Charts for further Diagnosis. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2200 Radiator Cooling Fan Motor: Service and Repair Fig. 1 Electric Cooling Fan Module Fig. 2 Electric Cooling Fan Module COMPONENT REPLACEMENT, COOLING FAN ^ Disconnect battery ground cable and electrical connector from fan motor. ^ Remove shroud clips and support bolts, nuts and washers. ^ Remove fan, motor and shroud or support as an assembly from radiator support. ^ Remove fan from motor shaft by supporting assembly on bench, remove retaining clip and sliding fan away. ^ Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations Radiator Fan Relay: Locations Radiator Fan Relay is located in the Power Distribution Center. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 2204 Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 2205 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions Radiator Fan Relay: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2208 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2209 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2210 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2211 Radiator Fan Relay: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2212 Radiator Fan Relay: Electrical Diagrams Air Conditioning System (Part 1 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2213 Air Conditioning System (Part 2 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2214 Air Conditioning System (Part 3 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2215 Air Conditioning System (Part 4 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2216 Radiator Fan System With Heater Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2217 Heater System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Technical Service Bulletins > Customer Interest for Fan Blade: > 07-06-98 > Nov > 98 > Cooling Module Fan - Vibrates/Comes Loose Fan Blade: Customer Interest Cooling Module Fan - Vibrates/Comes Loose NO: 07-06-98 GROUP: Cooling DATE: Nov. 20, 1998 SUBJECT: Cooling Module Fan Nut MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (International Market) DISCUSSION: Some subject vehicles may experience a loosening or loss of the nut retaining the engine cooling module fan causing a vibration initially. If not addressed promptly, the fan blade will not turn and the engine may overheat. A revised engine cooling module fan retaining nut kit has been released, p/n 05011946AA, to address this condition and should be used for repair any time this condition is experienced and the fan blade is not damaged. The cooling fan blade and motor were balanced as an assembly at the time of manufacture and must be properly oriented to minimize vibration. The cooling fan blade can be installed on the cooling motor shaft in one of two positions. If the cooling fan blade/motor assembly vibrates excessively after replacing the nut, remove and reinstall the cooling fan blade on the motor shaft 180 degrees from the first installation position. The proper torque for the revised fan retaining nut is 6.3-7.3 Nm (55-65 in. lbs.). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fan Blade: > 07-06-98 > Nov > 98 > Cooling Module Fan - Vibrates/Comes Loose Fan Blade: All Technical Service Bulletins Cooling Module Fan - Vibrates/Comes Loose NO: 07-06-98 GROUP: Cooling DATE: Nov. 20, 1998 SUBJECT: Cooling Module Fan Nut MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (International Market) DISCUSSION: Some subject vehicles may experience a loosening or loss of the nut retaining the engine cooling module fan causing a vibration initially. If not addressed promptly, the fan blade will not turn and the engine may overheat. A revised engine cooling module fan retaining nut kit has been released, p/n 05011946AA, to address this condition and should be used for repair any time this condition is experienced and the fan blade is not damaged. The cooling fan blade and motor were balanced as an assembly at the time of manufacture and must be properly oriented to minimize vibration. The cooling fan blade can be installed on the cooling motor shaft in one of two positions. If the cooling fan blade/motor assembly vibrates excessively after replacing the nut, remove and reinstall the cooling fan blade on the motor shaft 180 degrees from the first installation position. The proper torque for the revised fan retaining nut is 6.3-7.3 Nm (55-65 in. lbs.). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications NOTE: For information on how this type of sensor operates SEE, Powertrain Management/Computers and Control Systems/Coolant Temperature Sensor/Description and Operation. NOTE: Measure resistance using a high impedance Digital Volt Ohmmeter (DVOM). COLD CURVE (Reference voltage routed to sensor through PCM internal resistance of 10k ohm) Temperature ........................................................................................................................................ ........................................ Voltage -20° F ................................................................................................................................................... ....................................... 4.70 V -10° F ................................................................................................................................................... ....................................... 4.57 V 0° F ...................................................................................................................................................... ...................................... 4.45 V 10° F .................................................................................................................................................... ....................................... 4.30 V 20° F .................................................................................................................................................... ....................................... 4.10 V 30° F .................................................................................................................................................... ....................................... 3.90 V 40° F .................................................................................................................................................... ....................................... 3.60 V 50° F .................................................................................................................................................... ....................................... 3.30 V 60° F .................................................................................................................................................... ....................................... 3.00 V 70° F .................................................................................................................................................... ....................................... 2.75 V 80° F .................................................................................................................................................... ....................................... 2.44 V 90° F .................................................................................................................................................... ....................................... 2.15 V 100° F .................................................................................................................................................. ........................................ 1.83 V 110° F .................................................................................................................................................. ........................................ 1.57 V 120° F .................................................................................................................................................. ........................................ 1.25 V HOT CURVE (Reference voltage routed to sensor through PCM internal resistance of 10 k ohm) Temperature ........................................................................................................................................ ........................................ Voltage 110° F .................................................................................................................................................. ........................................ 4.20 V 120° F .................................................................................................................................................. ........................................ 4.00 V 130° F .................................................................................................................................................. ........................................ 3.77 V 140° F .................................................................................................................................................. ........................................ 3.60 V 150° F .................................................................................................................................................. ........................................ 3.40 V 160° F .................................................................................................................................................. ........................................ 3.20 V 170° F .................................................................................................................................................. ........................................ 3.02 V 180° F .................................................................................................................................................. ........................................ 2.80 V 190° F .................................................................................................................................................. ........................................ 2.60 V 200° F .................................................................................................................................................. ........................................ 2.40 V Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 2236 210° F .................................................................................................................................................. ........................................ 2.20 V 220° F .................................................................................................................................................. ........................................ 2.00 V 230° F .................................................................................................................................................. ........................................ 1.80 V 240° F .................................................................................................................................................. ........................................ 1.62 V 250° F .................................................................................................................................................. ........................................ 1.45 V Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 2237 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Crankshaft Position sensor screw .................................................................................................................................................... 12 Nm (105 in lbs) Camshaft Position sensor screw ...................................................................................................................................................... 12 Nm (105 in lbs) Coolant Sensor .......................................................................................................... .......................................................................... 7 Nm (60 in lbs) Ignition Coil .................................... ................................................................................................................................................ 12 Nm (105 in lbs) Ignition Switch ................................................................................................................... ................................................................. 2 Nm (17 in lbs) Spark Plugs ............................................. ........................................................................................................................................... 28 Nm (20 ft lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2238 Coolant Temperature Sensor/Switch (For Computer): Locations Ignition Coil And Coolant Temperature Sensor Location Sensor mounted under ignition coil. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2241 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2242 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2243 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2244 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2245 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2246 Coolant Sensor Circuit Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2247 Coolant Temperature Sensor/Switch (For Computer): Description and Operation LOCATION The Engine Coolant Temperature (ECT) sensor is threaded into the intake manifold, next to the thermostat housing. PURPOSE The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle speed, and ignition spark advance. OPERATION The sensor element extends into the coolant passage, where it maintains constant contact with the engine coolant. The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature increases, sensor resistance decreases.) The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below. As sensor resistance changes, the voltage drop across the sensor changes. The PCM translates the voltage drop across the sensor into engine coolant temperature. THEORY As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor (cold operation), or a 909 ohm resistor (warm operation). The resistance circuits are inside the PCM. For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the 10,000 ohm resistor. When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the 909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2248 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Coolant Temperature Sensor Resistance Test 1. With key off, disconnect connector from coolant temperature sensor. 2. Connect ohmmeter across coolant temperature sensor. Resistance should read as follows; - 700 to 1,000 Ohms at approximately 200°F (operating temperature). - 7,000 to 13,000 ohms at approximately 70°F, (room temperature). 3. If resistance is not within specifications, replace sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2249 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Ignition Coil And Coolant Temperature Sensor Location REMOVAL 1. Drain cooling system until coolant level is below sensor. 2. Disconnect coil pack electrical connector to sensor. 3. Remove coil mounting screws. 4. Rotate coil away from coolant temperature sensor. 5. Disconnect electrical connector from coolant temperature sensor. 6. Remove sensor from engine. INSTALLATION 1. Tighten the coolant sensor to 7 Nm (60 in lbs) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. 4. Install coil. Tighten coil mounting screws to 12 Nm (105 in lbs) torque. 5. Connect electrical connector to coil. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions Temperature Sensor (Gauge): Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 2255 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 2256 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 2257 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 2258 Temperature Sensor (Gauge): Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 2259 Engine Oil Pressure & Temp. System With Transmission Control Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Page 2260 Temperature Sensor (Gauge): Testing and Inspection When a malfunction occurs with a cluster gauge, before disassembling the cluster to check the gauge, check for a defective sending unit or wiring as follows: 1. Ground sending unit connector leads, at the sending unit, in the vehicle. 2. With ignition in ON position, a grounded input will cause the fuel or temperature gauge to read maximum or above. Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Controller/Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core Heater Core: Service and Repair Front Heater Core 1. Set parking brake and disconnect battery ground cable. 2. Discharge and recover system refrigerant. 3. Disconnect all engine compartment heater and air conditioning lines and vacuum hoses. 4. Drain engine coolant and plug lines. 5. Remove instrument panel as described in Instrument Panel/Service and Repair/Dash Panel Replacement. 6. Disconnect air conditioning hanger strap and temporarily reposition. 7. Remove rubber condensate drain tube and four mounting nuts in engine compartment. Fig. 10 A/C & Heater Assembly 8. Pull heater/air conditioning assembly to rear until unit studs clear dash panel, then drop unit down and remove from vehicle. 9. Place heater/air conditioning assembly on suitable workbench, then remove screw at vacuum harness and feed harness through hole in cover. 10. Remove thirteen screws from top cover, then remove top cover. 11. Remove screw from heater core tube retaining bracket, then lift heater core out of unit. 12. Remove evaporator core from unit. 13. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core > Page 2265 Heater Core: Service and Repair Rear Heater Core REMOVE AND INSTALL 1. Drain the engine coolant system. Rear Heater Plumbing 2. Disconnect heater tubing from the underbody heater lines to the rear unit. 3. Remove the lower left quarter trim panel. 4. Remove fan A/C distribution duct. 5. Remove heater-unit cover. 6. Carefully pull the heater core and heater tubes straight out of the unit. 7. Raise the heater core to drain residual coolant from the core. 8. Disconnect two heater hose clamps that attach plumbing to the heater core tube. 9. To install, reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hoses Heater Hose: Service and Repair Heater Hoses Review Safety Precautions and Warnings the in General Information section before proceeding with this operation. 1. Drain engine cooling system. 2. Loosen clamps at each end of heater hose to be removed. CAUTION: When removing hoses from heater core inlet or outlet nipples, do not use excessive force. Heater core may become damaged and leak engine coolant. 3. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the hose will not come off, slice the hose at the connector nipple and peal off heater hose. This method will require heater hose replacement. To install, reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hoses > Page 2271 Heater Hose: Service and Repair Underbody Plumbing WARNING: THE ENGINE COOLING SYSTEM MUST BE RELIEVED OF ALL PRESSURE. 1. Drain the engine cooling system. 2. In the engine compartment, and disconnect two auxiliary rear heater hoses from the (front) heater hose tee fittings. 3. Hoist the vehicle. Disconnect two push-together couplings from the auxiliary rear heater core tubes protruding through the floor pan. 4. Remove four bolts and one pal nut holding the plumbing to the floor pan and lower the plumbing from the vehicle. To Install, Reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair Radiator: Service and Repair 1. Disconnect battery ground cable, then drain cooling system. 2. Remove hose clamps and hoses from radiator, then remove coolant reserve tank tube. 3. Remove automatic transmission hoses and auxiliary oil cooler, if equipped. 4. Disconnect fan motor electrical connector, then remove fan and support assembly. 5. Remove upper shroud fasteners, then lift shroud up and out of bottom attaching clips. 6. Remove front grille, then remove air conditioning condenser fasteners and separate condenser from radiator. 7. Remove upper radiator mounting screws, then disconnect engine block heater wire, if equipped. 8. Lift radiator from engine compartment being careful not to damage cooling fins or water tubes. 9. Reverse procedure to install. Tighten to specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations Radiator Fan Relay: Locations Radiator Fan Relay is located in the Power Distribution Center. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 2279 Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 2280 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions Radiator Fan Relay: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2283 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2284 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2285 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2286 Radiator Fan Relay: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2287 Radiator Fan Relay: Electrical Diagrams Air Conditioning System (Part 1 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2288 Air Conditioning System (Part 2 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2289 Air Conditioning System (Part 3 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2290 Air Conditioning System (Part 4 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2291 Radiator Fan System With Heater Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 2292 Heater System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications NOTE: For information on how this type of sensor operates SEE, Powertrain Management/Computers and Control Systems/Coolant Temperature Sensor/Description and Operation. NOTE: Measure resistance using a high impedance Digital Volt Ohmmeter (DVOM). COLD CURVE (Reference voltage routed to sensor through PCM internal resistance of 10k ohm) Temperature ........................................................................................................................................ ........................................ Voltage -20° F ................................................................................................................................................... ....................................... 4.70 V -10° F ................................................................................................................................................... ....................................... 4.57 V 0° F ...................................................................................................................................................... ...................................... 4.45 V 10° F .................................................................................................................................................... ....................................... 4.30 V 20° F .................................................................................................................................................... ....................................... 4.10 V 30° F .................................................................................................................................................... ....................................... 3.90 V 40° F .................................................................................................................................................... ....................................... 3.60 V 50° F .................................................................................................................................................... ....................................... 3.30 V 60° F .................................................................................................................................................... ....................................... 3.00 V 70° F .................................................................................................................................................... ....................................... 2.75 V 80° F .................................................................................................................................................... ....................................... 2.44 V 90° F .................................................................................................................................................... ....................................... 2.15 V 100° F .................................................................................................................................................. ........................................ 1.83 V 110° F .................................................................................................................................................. ........................................ 1.57 V 120° F .................................................................................................................................................. ........................................ 1.25 V HOT CURVE (Reference voltage routed to sensor through PCM internal resistance of 10 k ohm) Temperature ........................................................................................................................................ ........................................ Voltage 110° F .................................................................................................................................................. ........................................ 4.20 V 120° F .................................................................................................................................................. ........................................ 4.00 V 130° F .................................................................................................................................................. ........................................ 3.77 V 140° F .................................................................................................................................................. ........................................ 3.60 V 150° F .................................................................................................................................................. ........................................ 3.40 V 160° F .................................................................................................................................................. ........................................ 3.20 V 170° F .................................................................................................................................................. ........................................ 3.02 V 180° F .................................................................................................................................................. ........................................ 2.80 V 190° F .................................................................................................................................................. ........................................ 2.60 V 200° F .................................................................................................................................................. ........................................ 2.40 V Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 2299 210° F .................................................................................................................................................. ........................................ 2.20 V 220° F .................................................................................................................................................. ........................................ 2.00 V 230° F .................................................................................................................................................. ........................................ 1.80 V 240° F .................................................................................................................................................. ........................................ 1.62 V 250° F .................................................................................................................................................. ........................................ 1.45 V Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 2300 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Crankshaft Position sensor screw .................................................................................................................................................... 12 Nm (105 in lbs) Camshaft Position sensor screw ...................................................................................................................................................... 12 Nm (105 in lbs) Coolant Sensor .......................................................................................................... .......................................................................... 7 Nm (60 in lbs) Ignition Coil .................................... ................................................................................................................................................ 12 Nm (105 in lbs) Ignition Switch ................................................................................................................... ................................................................. 2 Nm (17 in lbs) Spark Plugs ............................................. ........................................................................................................................................... 28 Nm (20 ft lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2301 Coolant Temperature Sensor/Switch (For Computer): Locations Ignition Coil And Coolant Temperature Sensor Location Sensor mounted under ignition coil. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2304 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2305 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2306 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2307 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2308 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2309 Coolant Sensor Circuit Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2310 Coolant Temperature Sensor/Switch (For Computer): Description and Operation LOCATION The Engine Coolant Temperature (ECT) sensor is threaded into the intake manifold, next to the thermostat housing. PURPOSE The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle speed, and ignition spark advance. OPERATION The sensor element extends into the coolant passage, where it maintains constant contact with the engine coolant. The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature increases, sensor resistance decreases.) The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below. As sensor resistance changes, the voltage drop across the sensor changes. The PCM translates the voltage drop across the sensor into engine coolant temperature. THEORY As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor (cold operation), or a 909 ohm resistor (warm operation). The resistance circuits are inside the PCM. For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the 10,000 ohm resistor. When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the 909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2311 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Coolant Temperature Sensor Resistance Test 1. With key off, disconnect connector from coolant temperature sensor. 2. Connect ohmmeter across coolant temperature sensor. Resistance should read as follows; - 700 to 1,000 Ohms at approximately 200°F (operating temperature). - 7,000 to 13,000 ohms at approximately 70°F, (room temperature). 3. If resistance is not within specifications, replace sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2312 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Ignition Coil And Coolant Temperature Sensor Location REMOVAL 1. Drain cooling system until coolant level is below sensor. 2. Disconnect coil pack electrical connector to sensor. 3. Remove coil mounting screws. 4. Rotate coil away from coolant temperature sensor. 5. Disconnect electrical connector from coolant temperature sensor. 6. Remove sensor from engine. INSTALLATION 1. Tighten the coolant sensor to 7 Nm (60 in lbs) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. 4. Install coil. Tighten coil mounting screws to 12 Nm (105 in lbs) torque. 5. Connect electrical connector to coil. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions Temperature Sensor (Gauge): Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 2318 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 2319 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 2320 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 2321 Temperature Sensor (Gauge): Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 2322 Engine Oil Pressure & Temp. System With Transmission Control Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Page 2323 Temperature Sensor (Gauge): Testing and Inspection When a malfunction occurs with a cluster gauge, before disassembling the cluster to check the gauge, check for a defective sending unit or wiring as follows: 1. Ground sending unit connector leads, at the sending unit, in the vehicle. 2. With ignition in ON position, a grounded input will cause the fuel or temperature gauge to read maximum or above. Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Controller/Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair Thermostat: Service and Repair WARNING: Do not remove pressure cap with the system hot and under pressure. Serious burns from coolant can occur. REMOVAL 1. With a suitable container placed below draincock, drain engine coolant below level of thermostat. 2. Remove thermostat housing bolts, then the housing. 3. Remove thermostat and gasket, then discard gasket and clean mating surfaces. NOTE: The thermostat is in a water box, formed in the drive belt side of the intake manifold. INSTALLATION Place a new gasket (dipped in water) on the water box surface, center thermostat into opening in the intake manifold. Place housing over gasket and thermostat, making sure thermostat is in recess provided. Bolt housing to intake manifold, tighten bolts to 28 Nm (250 in.lbs.). Refill cooling system. See Cooling System/Service and Repair. See: Service and Repair Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Testing and Inspection > Verifying Water Pump Problem Water Pump: Testing and Inspection Verifying Water Pump Problem VERIFYING WATER PUMP PROBLEM Check for Loose Water Pump Pulley As the pump shaft seals and bearings wear with age the pulley/shaft may develop a wobble or lateral runout. With the engine off and the key removed from the ignition, attempt to move the pulley from side to side and back and forth. There should be no detectable movement. The pulley should turn smoothly, with no rough spots. The water pump should be replaced if any pulley wobble is detected. If the water pump is not replaced the pump shaft may eventually seize or break. NOTE: Incorrect belt tension (too tight) may cause premature wear of the bearings and seals. WARNING: Never remove a radiator cap while the engine is hot. Severe personal injury may result. Inspect for Leakage 1. With the engine "OFF" and cold: - Check coolant level and refill if necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Testing and Inspection > Verifying Water Pump Problem > Page 2331 - Inspect the water pump for leakage. Closely check the following areas: Inspection (weep) hole. - Pump shaft. - Gasket. 2. Pressurize the cooling system with a pressure tester and again check for leaks. Do not exceed the rated pressure of the radiator cap. NOTE: If any leaks are found, verify that they are not originating from a component near or above the water pump (i.e. thermostat, loose radiator hoses, intake gasket, engine coolant temperature sensor) CAUTION: When finished, immediately re-install the radiator cap. 3. If no leaks are found, start and warm the engine until the thermostat opens. Stop the engine and check for fresh leakage around the water pump shaft. NOTE: Occasionally water pumps will only leak around the shaft seals while the shaft is rotating. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Testing and Inspection > Verifying Water Pump Problem > Page 2332 Water Pump: Testing and Inspection After Repairs Operational Check COOLING SYSTEM OPERATIONAL CHECK IMPORTANT: Always verify the operation of the thermostat and cooling fan prior to driving the vehicle after a cooling system repair. HOW - With the cooling system filled with coolant and the radiator cap installed, start the engine and allow the coolant to warm up. - The upper radiator hose should remain cool to the touch until the coolant within the engine block and head has reached the thermostat opening temperature. The thermostat opening should be indicated by a rapid warm up of the upper radiator hose. - If upper hose gradually warms up, the thermostat may be stuck open (assuming the engine is started cold) - If the coolant temperature reaches the normal operating temperature (as indicated by the temperature gauge) before the upper hose becomes warm, the engine should be turned off, and the cooling system allowed to cool down. The thermostat may be stuck closed and should be removed and tested. WARNING: Never remove the radiator cap, or disconnect a coolant hose on a warm engine. A warm cooling system may contain a large amount of stored energy in the form of steam and high pressure, which could seriously injure you. - If the thermostat opened properly, continue to allow the cooling system to warm up. As the coolant temperature reaches its maximum operating temperature the electrical cooling fan should energize. Verify the fan energizes and de-energizes. WHY Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Testing and Inspection > Verifying Water Pump Problem > Page 2333 Thermostat Closed, Cold Engine - With the thermostat closed, coolant flow through the radiator is blocked forcing the coolant to re-circulate through the block and head. This allows for a rapid warm up. During this time there should be little or no coolant flow through the upper radiator hose. Thermostat Open, Warm Engine - Once the coolant has reached normal operating temperature, the thermostat begins to open, allowing coolant flow through the upper hose and into the radiator. The thermostat will continue to regulate the amount of coolant flow to the radiator to maintain a "Minimum" operating temperature. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Testing and Inspection > Verifying Water Pump Problem > Page 2334 Water Pump: Testing and Inspection After Repairs Leak Check AFTER REPAIRS LEAK CHECK PURPOSE Initially fill the cooling system and check for leaks prior to starting the engine and bleeding the system. Although the system will not be completely full, any leaks which are detected may be fixed before the engine and cooling system are hot. NOTE: It is much easier to repair a leak on a cold engine than on a hot engine. HOW - Fill the cooling system until the radiator is full. - Apply pressure to the system with a pressure tester. - Carefully check for leaks around: All hoses and clamps. - Water pump sealing surfaces. - Any cooling system component which was removed or replaced. - If no leaks are detected continue with the fill and bleed procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Removal Water Pump: Service and Repair Removal Fig. 6 Water Pump REMOVE 1. Drain Cooling System. 2. Remove Accessory Drive Belt. 3. Remove right front lower fender shield. 4. Remove pump pulley bolts and remove pulley. 5. Remove pump mounting screws Remove pump. Fig. 7 Water Pump Body 6. Remove and discard O-ring seal. 7. Clean O-ring groove and O-ring surfaces on pump and chain case cover. Take care not to scratch or gouge sealing surface. INSPECT NOTE: Replace the water pump if it has any of the following defects. 1. Damage or cracks on the pump body. 2. Coolant leaks; if the seal is leaking, evident by traces of coolant leaks from vent hole. 3. Loose or rough turning bearing. 4. Impeller - rubs either the pump body or chain case cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Removal > Page 2337 Water Pump: Service and Repair Installation Fig. 7 Water Pump Body Fig. 6 Water Pump INSTALL 1. Install new O-ring in O-ring groove. 2. Install pump to chain case cover. Torque screws to 12 Nm (105 in.lbs.). 3. Rotate pump by hand to check for freedom of movement. 4. Position pulley on pump. Install screws and torque to 30 Nm (250 in.lbs.). 5. Install drive belt. See Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair. See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair 6. Install right front lower fender shield. 7. Refill Cooling System. See Cooling System/Service and Repair. See: Service and Repair Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Page 2338 Water Pump: Tools and Equipment RECOMMENDED TOOLS - Drip pan - For draining coolant. - Torque Wrenches (0-30 in lbs). - Full set of Metric sockets and wrenches. - Fender covers. OPTIONAL - Radiator hose removal tool. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Page 2339 - Cooling system pressure tester. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations Water Pump: Fundamentals and Basics Initial Preparations INITIAL PREPARATIONS Disconnect Battery When working near or around the cooling fan or drive belts, accidentally engaging the starter or cooling fan can result in serious personal injury. The negative battery terminal should be disconnected prior to commencing work and should not be reconnected until after the water pump is installed and the engine is ready to restart. Fender Covers Fender covers will prevent damage to the vehicles finish while performing the job. NOTE: A fender cover folded over the radiator will prevent accidental damage to the radiator. The radiator can be easily damaged should a wrench slip off of a bolt while working on the water pump. Coolant Drip Pan Pre-position a drip pan under the vehicle to prevent any incidental spills. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 2342 Water Pump: Fundamentals and Basics Removal Tips and Hints WATER PUMP REMOVAL NOTES, WARNINGS, AND HINTS FROZEN AND BROKEN BOLTS Frozen and broken bolts are often a major problem when removing water pumps. Coolant can seep into the bolt holes resulting in corrosion and frozen bolts. Prior to starting the job, spray all water pump retaining bolts with a penetrating oil. Upon removal, any bolt or nut which shows signs of corrosion should be replaced. The threads of the associated bolt hole should be re-tapped or chased. Inspect the coolant hoses, drive belts, and associated pulleys. Since these components will need to be removed to replace the timing belt it would be convenient/time saving to have any necessary replacement parts on hand prior to removing the pump. COOLANT HOSES Inspect the hoses for the following: Cracks, especially near the hose clamps. - Swelling, look for areas of the hose that appear unnaturally bulged outwards. NOTE: This is often caused by improper removal techniques, see Hose Removal in this article. - Oil contamination and soft spots. Oil contamination breaks down the structure of the rubber and significantly weakens the hose. NOTE: The oil leak should be fixed prior to replacing the hose. - Hard or brittle hoses, as the hoses age the rubber looses its resiliency and becomes brittle. The hoses need to be able to flex to compensate for the movement of the engine. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 2343 DRIVE BELTS Small cracks that run across that run across the ribbed surface of the belt from rib to rib , are considered normal, These are not reasons to replace the belt. If chunks of belt material are missing between the cracks, the belt should be replaced. Cracks running along the rib (not across) are not normal. Any belts with cracks running along the rib should be replaced. Replace the belt if it has excessive wear, frayed cords or severe glazing. Drive Pulleys - Verify the pulleys have no side to side wobble, and rotate freely. Replace if necessary. - Verify the pulleys are properly aligned. Adjust or replace as necessary. Belt Removal Do not attempt to bump the drive belts off with the starter. This practice can damage the belt, pulley, and technician. Removing the belt by relaxing the tension will allow you to correctly adjust the tension when installing the belt. DRIP PAN Prior to removing any hose or the water pump, place a large drip pan under the engine. Although the coolant may be drained from the radiator, there is still a large amount of residual coolant trapped in the hoses and water pump. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 2344 HOSE REMOVAL Prior to pulling the hose from the fitting, rotate/twist the hose on the fitting to break the grip of any corrosion present. If the hose is to be replaced, it may be quicker to cut hose from the fitting. CAUTION: When cutting the hose be careful not to damage the fitting. A radiator hose removal tool may help free up stubborn hoses. CAUTION: Do not use any device to pry the hose off of the fitting. - If at any time a tearing or ripping sound is heard (though the hose appears fine) the hose should be replaced. The sound is coming from the internal reinforcing fibers embedded in the hose. Once the fibers have been broken the hose will be subject to swelling and rupture when pressure is applied. WATER PUMP REMOVAL After removing the retaining bolts the water pump may still be stuck to the engine. The original gasket sealant may cause the pump to firmly stick to engine. A few soft blows from a rubber mallet or block of wood will generally loosen the pump. CAUTION: Verify that ALL of the retaining bolts are removed. - Do not pry between the pump and the gasket. This may damage the pump sealing surface. - Upon breaking the seal, a large amount of coolant trapped in the block will generally pour out from the water pump opening. Be sure to have a drip pan prepositioned. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 2345 Water Pump: Fundamentals and Basics Installation Tips and Hints WATER PUMP INSTALLATION NOTES - Compare the old pump to the new pump and verify: Shaft lengths match exactly. - Retaining bolt holes match exactly. - Verify the retaining bolts and bolt holes have clean threads. Re-tap or chase the threads as necessary. - Do not over tighten the retaining bolts, use a torque wrench to properly tighten the bolts to the correct specification. CAUTION: Water pump retaining bolts may be easily broken or stripped, do not tighten the retaining bolts with an air wrench or impact gun. - When tightening hose clamps: Position the hose squarely on the fitting. - Verify the hose clamp is clear of the retaining rim on the fitting. Do not over tighten the clamps. - While working on the cooling system it is a good habit to clean the radiator and A/C condenser fins of bugs and dirt. This build up of debris can seriously reduce the cooling ability of the system. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Fundamentals and Basics > Initial Preparations > Page 2346 Water Pump: Fundamentals and Basics Recommended Parts RECOMMENDED PARTS - New water pump O-ring. - Engine Coolant: NOTE: For optimum performance, use 50/50 mixture of high quality ethylene glycol coolant and water. OPTIONAL, PENDING INSPECTION - Radiator hoses. - Drive belt. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 110396 > Jun > 96 > Catalytic Converter - Excessive Sulfur Odor Catalytic Converter: Customer Interest Catalytic Converter - Excessive Sulfur Odor NO: 11-03-96 GROUP: Exhaust EFFECTIVE DATE: June 17, 1996 SUBJECT: Excessive Sulphur Odor MODELS: 1992-1995 (AA) Acclaim/Spirit/LeBaron Sedan 1992-1993 (AC) Dynasty/New Yorker/New Yorker Salon 1992-1993 (AG) Daytona 1992-1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992-1994 (AP) Sundance/Shadow/Shadow Convertible 1993-1995 (AS) Caravan/Voyager/Town & Country NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 2.2L OR 2.5L ENGINES ONLY. SYMPTOM/CONDITION: New catalytic converters are now available to address customer complaints of excessive hydrogen sulfide odor (rotten egg smell) coming from the tailpipe of their vehicles at idle. These catalysts were specially manufactured with a revised internal coating which minimizes sulphur odor. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves the replacement of the catalytic converter with a revised part. Replace the catalytic converter following the repair procedures given in group 11 of the appropriate service manual. POLICY: Reimbursable within the provisions of the warranty, TIME ALLOWANCE: Labor Operation No: 11-50-01-91 0.7 Hrs. FAILURE CODE: P8-New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 110396 > Jun > 96 > Catalytic Converter - Excessive Sulfur Odor Catalytic Converter: All Technical Service Bulletins Catalytic Converter - Excessive Sulfur Odor NO: 11-03-96 GROUP: Exhaust EFFECTIVE DATE: June 17, 1996 SUBJECT: Excessive Sulphur Odor MODELS: 1992-1995 (AA) Acclaim/Spirit/LeBaron Sedan 1992-1993 (AC) Dynasty/New Yorker/New Yorker Salon 1992-1993 (AG) Daytona 1992-1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992-1994 (AP) Sundance/Shadow/Shadow Convertible 1993-1995 (AS) Caravan/Voyager/Town & Country NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 2.2L OR 2.5L ENGINES ONLY. SYMPTOM/CONDITION: New catalytic converters are now available to address customer complaints of excessive hydrogen sulfide odor (rotten egg smell) coming from the tailpipe of their vehicles at idle. These catalysts were specially manufactured with a revised internal coating which minimizes sulphur odor. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves the replacement of the catalytic converter with a revised part. Replace the catalytic converter following the repair procedures given in group 11 of the appropriate service manual. POLICY: Reimbursable within the provisions of the warranty, TIME ALLOWANCE: Labor Operation No: 11-50-01-91 0.7 Hrs. FAILURE CODE: P8-New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2361 Exhaust System - FWD Minivans Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2362 Catalytic Converter: Description and Operation Three Way Catalyst (TWC) PURPOSE Reduces emission of the three major pollutants, (Carbon Monoxide (CO), Hydrocarbon (HC) and Oxides of Nitrogen (NOx)), by up to 90%. OPERATION Oxidation Reaction As exhaust gasses pass through converter, the platinum in the converter triggers an oxidation (burning) reaction. During this process the HC and CO combine with oxygen, forming water vapor (H2O) and Carbon Dioxide (CO2). This process no effect on NOx emissions. Reduction Reaction The Rhodium in the converter converts the NOx into nitrogen and oxygen, in a "reduction" (removal of oxygen), reaction. OPERATING ENVIRONMENT A complete catalytic reaction requires that the air/fuel mixture remains near 14.7:1. This can only be achieved in a properly functioning feedback system with oxygen sensor. The ideal converter operating temperature, for maximum emission reduction and long service life is, 400°C - 800°C (750°F - 1500°F). Engine malfunctions, (for example misfires), can cause temperatures in the converter to excede 1400°C (2500°F), which can melt substrate material. CONSTRUCTION Converter consists of: metal housing, ceramic grid substrate, and catalytic coating, (approximately 2 grams of platinum and rhodium). CAUTION: Never use leaded fuel, as lead compounds tend to coat pores and active material, reducing or eliminating catalyst activity. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2363 Catalytic Converter: Service and Repair Exhaust System - FWD Minivans REMOVAL 1. Remove clamp holding muffler to converter. 2. Remove muffler from converter (it may be necessary to heat the pipe connection). 3. Remove clamp securing converter to header pipe. 4. Remove converter from header pipe (it may be necessary to heat the pipe connection). INSTALLATION 1. Install converter to header pipe with a new clamp. 2. Reposition rear exhaust pipe hanger. 3. Install muffler to converter with a new clamp. 4. Start the engine and inspect for exhaust leaks NOTE: Replace any missing or damaged heat shields. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications TORQUE SPECIFICATIONS Heat Shield Mounting Screws ............................................................................................................. ................................................... 8 Nm ( 75 in.lbs.) Heat Shield Mounting Nuts ................................. ................................................................................................................................. 5 Nm ( 45 in.lbs.). Insulator Mounting Bolts ......................................................................................................... .......................................................... 17 Nm (150 in.lbs.) U-Bolt Nuts & Uni-Clamp Nut .......................................................................................................................................................... 28 Nm (250 in.lbs.) Exhaust Flange Nuts ............................................................................................ .............................................................................. 28 Nm (250 in.lbs.) Exhaust Manifold Mounting Stud ...................................................................................................................................................... 23 Nm (200 in.lbs.) Exhaust Manifold Mounting Screws .................................................................................................................................................. 23 Nm (200 in.lbs.) Exhaust Manifold Crossover Bolts ....................................................................................................................................................... 33 Nm (25 ft.lbs.) Exhaust Manifold Crossover Nuts ........................................................................................................................................................ 33 Nm (25 ft.lbs.) Heat Shield Mounting Screws ............................................................................................................................................................ 23 Nm (200 in.lbs.) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2367 Exhaust Manifold: Service and Repair REMOVAL 1. Raise vehicle and disconnect exhaust pipe from rear (cowl side) exhaust manifold at articulated joint. Fig. 16 EGR Tube, Heated Oxygen Sensor And Alternator/Power Steering Strut 2. Separate EGR tube from rear manifold and disconnect Heated Oxygen Sensor lead wire. 3. Remove Alternator/Power Steering Support Strut. 4. Remove bolts attaching cross-over pipe to manifold. 5. Remove bolts attaching rear manifold to cylinder head and remove manifold. Fig. 17 Heat Shield 6. Lower vehicle and remove screws attaching front heat shield to front manifold. Fig. 18 Crossover Pipe 7. Remove bolts fastening crossover pipe to front exhaust manifold and nuts fastening manifold to cylinder head. Remove assemblies. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2368 Fig. 19 Check Exhaust Manifold Mounting Surface INSPECTION Inspect exhaust manifolds for damage or cracks and check distortion of the cylinder head mounting surface and exhaust crossover mounting surface with a straightedge and thickness gauge. INSTALLATION 1. Install rear exhaust manifold and tighten attaching bolts to 23 Nm (200 in.lbs.). 2. Attach exhaust pipe to exhaust manifold and tighten shoulder bolt to 28 Nm (250 in.lbs.). 3. Attach crossover pipe to exhaust manifold and tighten bolt to 33 Nm (25 ft.lbs.) and connect oxygen sensor lead. 4. Reinstall EGR Tube and Alternator/Power Steering Strut. 5. Install front exhaust manifold and attach exhaust crossover. 6. Install front manifold heat shield and tighten attaching screws to 23 Nm (200 in.lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly Body Controller: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 2380 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly Body Controller: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly > Page 2386 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > Page 2387 Body Control Module System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Body Controller: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2390 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2391 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2392 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2393 Body Controller: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2394 Body Controller: Connector Views Body Control Module Blue Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2395 Body Control Module Natural Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2396 BCM Natural Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2397 BCM Blue Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and ID > BCM Identification Body Controller: Application and ID BCM Identification There are two different body control modules available on these vehicles; One supports the mechanical instrument cluster as well as the electro/mechanical instrument cluster. - The other supports the electronic instrument cluster. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and ID > BCM Identification > Page 2400 Body Controller: Application and ID Glossary of Terms BCM - Body Control Module CCD - Chrysler Collision Detection (Vehicle Communications Bus) CMTC - Compass/mini-trip Computer (module) DLC - Data Link Connector (previously Called "Diagnostic Connector") DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument Cluster ET - Elapsed Time IOD - Ignition Off Draw MET - Metric MIC - Mechanical Instrument Cluster ODO - Odometer PCM - Powertrain Control Module PDC - Power Distribution Center RKE Remote Keyless Entry Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and ID > Page 2401 Body Controller: Description and Operation PURPOSE The body control module: Provides power or ground for a variety of systems and uses a voltage drop to monitor these systems. - Is the only module that has the capability of providing both bias and termination on the CCD bus system. - Is used to store odometer information displayed in the electronic instrument cluster. OPERATION The body systems are monitored by individual control modules, which send information about their operation to the body control module over the CCD (Chrysler Collision Detection multiplex system) bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed to the appropriate module(s). - Each module receives the same information about a component or circuit as another module does. - This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. BODY SYSTEM COVERAGE: - Automatic Door Locks - Compass/mini-trip Module - Courtesy Lamps - Electronic Instrument Cluster (EIC) - Electro/mechanical Instrument Cluster - Mechanical Instrument Cluster (MIC) - Illuminated Entry - Remote Keyless Entry (RKE) - Intermittent Wipers - Liftgate Release NOTE: Communication over the CCD bus is essential to the proper operation of vehicle on-board diagnostic systems and scan tool communication. Bus or scan tool problems must be corrected before proceeding with diagnostic testing. If there is a problem, refer to Vehicle Communications (CCD) Bus/Testing and Inspection for diagnosis and repair procedures. TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is not set or if it is set incorrectly, any speed-related accessories will not operate or will operate inaccurately. - This includes the speedometer, speed control, rolling door locks, and other devices that are operated by the powertrain and body controllers. - For instructions on setting the pinion factor, see the appropriate transmission section. GLOSSARY OF TERMS BCM - Body Control Module CCD - Chrysler Collision Detection (vehicle Communications Bus) CMTC - Compass/mini-trip Computer (module) DLC - Data Link Connector (previously Called "diagnostic Connector") DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument Cluster ET - Elapsed Time IOD - Ignition Off Draw MET - Metric MIC - Mechanical Instrument Cluster ODO - Odometer PCM - Powertrain Control Module PDC - Power Distribution Center RKE Remote Keyless Entry Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Controller: Component Tests and General Diagnostics Diagnostic Notes - Read First TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is not set or if it is set incorrectly, any speed-related accessories will not operate or will operate inaccurately. - This includes the speedometer, speed control, rolling door locks, and other devices that are operated by the powertrain and body controllers. - For instructions on setting the pinion factor, see the appropriate transmission section. NOTE: These diagnostics are based on the failure condition or symptom being present at the time of diagnosis. TIPS: Verify that the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Be careful when performing electrical tests to prevent accidental shorting of terminals. Such mistakes can damage fuses or components and will sometimes set a second code, making diagnosis of the original problem more difficult. WARNINGS: - When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as watchbands or bracelets that might make an inadvertent electrical contact. - When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests. To efficiently diagnose CCD bus problems follow these six steps: 1. Verify Complaint 2. Check for Related Symptoms 3. Analyze Symptoms 4. Isolate the Problem 5. Repair the Isolated Problem 6. Verify Proper Operation ROAD TESTING Some complaints will require a test drive to duplicate the diagnostic code or symptom condition and to verify the repair. CAUTIONS: Before road testing a vehicle, be sure that all components are reassembled. - During the test drive, do not try to read the scan tool screen while in motion. - Do not hang the scan tool from the rear view mirror or operate it yourself. Have an assistant available to operate the scan tool. TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is not set or if it is set incorrectly, any speed-related accessories will not operate or will operate inaccurately. - This includes the speedometer, speed control, rolling door locks, and other devices that are operated by the powertrain and body controllers. - For instructions on setting the pinion factor, see the appropriate transmission section. Description of On-Board Diagnostics A scan tool is required to read body system trouble codes. However, not all body system problems have a corresponding trouble code. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2404 Body Controller: Scan Tool Testing and Procedures If the scan tool Does Not Power Up; Check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). If all connections are proper between scan tool and the vehicle, and the vehicle battery is fully charged, an inoperative scan tool may be the result or faulty cable or vehicle wiring. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and Inspection > Page 2405 Body Controller: Tools and Equipment The following tools are recommended to properly diagnose CCD bus problems: - Scan tool -- with correct cartridge and applicable connectors. - Jumper Wires - Ohmmeter - Oil Pressure Gauge - Voltmeter Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > High Altitude Kit - Installation Powertrain Control Module: Technical Service Bulletins High Altitude Kit - Installation NO.: 25-01-93 GROUP: Emissions DATE: Sep. 3, 1993 SUBJECT: High Altitude Kits MODELS: 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country SYMPTOM/CONDITION: The 1994 AS Body Owners Manual makes reference to the availability of high altitude kits (1st page of the Starting and Operating section) that can be used if the owner changes his residence from an area of low altitude to one of high altitude. These kits are required by the EPA for some 1994 federally certified AS body vehicles to comply with high altitude emissions standards. The high altitude kit will have no effect on vehicle performance or driveability. DIAGNOSIS: Vehicles for which these kits are available have the following statement on the Vehicle Emission Control Information (VECI) label: "CONVERSION KIT REQUIRED FOR HIGH ALTITUDE - SEE OWNERS MANUAL". The high altitude kit must be installed if requested by the vehicle owner, at the owner's expense. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the PCM, VECI label and installing an Authorized Modification label. 1. Using the procedure outlined on either page 14-51 or 14-112 of the 1994 Front Wheel Drive/All Wheel Drive Van/Wagon Service Manual, replace the PCM with the appropriate PCM specified in the "Parts Required" section of this bulletin. 2. Use Mopar Tar Remover (P/N 4549601) to clean the surface of the VECI label and the area of the dash panel that the new labels will be attached to. 3. Attach the new VECI label on top of the original label. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > High Altitude Kit - Installation > Page 2410 4. Type in the required information on the Authorized Modification label (P/N 4275086) as illustrated, and attach next to the VECI label. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations Powertrain Control Module (PCM) And Data Link Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 2413 Powertrain Control Module (PCM) And Data Link Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2416 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2417 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2418 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2419 Powertrain Control Module: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2420 Powertrain Control Module 60 Way Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Auto Sutdown Relay In the Power Distribution Center left side of engine compartment. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2424 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2425 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2428 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2429 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2430 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2431 Automatic Shut Down (ASD) Relay: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2432 Automatic Shut Down (ASD) Relay: Description and Operation Relay Locations PURPOSE Relay supplies battery voltage to the ignition coil and fuel injector(s). OPERATION Ignition switch in the START or RUN position, and PCM is receiving reference signals from the distributor pick-up. The Powertrain Control Module (PCM) activates the relay (by supplying a ground). If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM interrupts the relay ground and no voltage is supplied to the ignition coil, or fuel injector(s). NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through the same ground circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay NOTE: Relay terminal numbers can be found on the bottom of the relay: TERMINAL IDENTIFICATION - Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times. - Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the components being operated. - Terminal number 86 is connected to a switched (B+) power source (ignition in ON or RUN). - Terminal number 85 is grounded by the PCM. PROCEDURE 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value (ohms) should be 75 ± 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 Volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. Continuity should now be present between terminals number 87 and 30. Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 Volt power source. - If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring Diagrams for fuel system wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center (Relay Locations) Fuel Pump Relay Socket Fuel pump relay is located in LH side of engine compartment in the power distribution center. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2439 Fuel Pump Relay: Description and Operation Relay Locations PURPOSE Relay supplies battery voltage to the fuel pump and oxygen sensor heater element, when grounded by the Powertrain Control Module (PCM). OPERATION The PCM grounds the relay when the ignition switch is in the START or RUN position and the PCM is receiving reference signals from the distributor pick-up. If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM interrupts the relay ground and no voltage is supplied to the fuel pump and oxygen sensor heater element. NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through the same ground circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2440 Fuel Pump Relay: Testing and Inspection NOTE: The relay terminal numbers can be found on the bottom of the relay: TERMINAL IDENTIFICATION - Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times. ^ Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the component being operated. - Terminal number 86 is connected to a switched (+) power source. - Terminal number 85 is grounded by the PCM. PROCEDURE 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value (ohms) should be 75 ± 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 Volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. Continuity should now be present between terminals number 87 and 30. Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 Volt power source. - If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring Diagrams for fuel system wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Auto Sutdown Relay In the Power Distribution Center left side of engine compartment. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2444 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2445 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2448 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2449 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2450 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2451 Automatic Shut Down (ASD) Relay: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2452 Automatic Shut Down (ASD) Relay: Description and Operation Relay Locations PURPOSE Relay supplies battery voltage to the ignition coil and fuel injector(s). OPERATION Ignition switch in the START or RUN position, and PCM is receiving reference signals from the distributor pick-up. The Powertrain Control Module (PCM) activates the relay (by supplying a ground). If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM interrupts the relay ground and no voltage is supplied to the ignition coil, or fuel injector(s). NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through the same ground circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay NOTE: Relay terminal numbers can be found on the bottom of the relay: TERMINAL IDENTIFICATION - Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times. - Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the components being operated. - Terminal number 86 is connected to a switched (B+) power source (ignition in ON or RUN). - Terminal number 85 is grounded by the PCM. PROCEDURE 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value (ohms) should be 75 ± 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 Volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. Continuity should now be present between terminals number 87 and 30. Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 Volt power source. - If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring Diagrams for fuel system wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2460 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2461 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2462 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2463 Ignition Control Module: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2470 Camshaft Position Sensor: Mechanical Specifications Camshaft Position sensor screw ..................................................................................................................................................... 14 Nm (125 in lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor Location The Camshaft Position (CMP) sensor is located on the timing gear cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 2473 Camshaft Position Sensor Location Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2476 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2477 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2478 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2479 Camshaft Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2480 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2481 Camshaft Position Sensor: Electrical Diagrams Camshaft Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2482 Camshaft Position Sensor: Description and Operation Camshaft Sensor PURPOSE - Sensor provides PCM with cylinder identification. - PCM uses sensor input to determine fuel injection sequence and ignition timing. OPERATION Sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). - When a notch aligns with the sensor, voltage spikes high (5.0 volts). - As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. - The number of notches determine the amount of pulses. NOTE: If available, an oscilloscope can display the square wave patterns of each timing event. NOTE: The arrows and cylinder call outs on the following image represent which cylinder the flat spot and notches identify, they do not indicate Top Dead Center (TDC) position. Camshaft Sprocket - When the PCM receives two cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder # 1 are next (on driveplate). - When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number # 2 crankshaft timing marks are next. - After 3 camshaft pulses, the PCM knows cylinder # 4 crankshaft timing marks follow. - One camshaft pulse after the three pulses indicates cylinder # 5. - The two camshaft pulses after cylinder 5 signals cylinder # 6. - The PCM can synchronize on cylinders 1 or 4. NOTE: TDC does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. NOTE: The distance between the sensor and camshaft sprocket is critical to system operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE Powertrain Management/Computers and Control Systems/Camshaft Position Sensor/Service and Repair. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2483 Camshaft Position Sensor: Service and Repair Fig. 7 Camshaft Position Sensor REMOVAL 1. Disconnect sensor electrical connector (Fig. 7). 2. Remove engine mount support bracket. 3. Loosen camshaft position sensor retaining bolt enough to allow slot in sensor to slide past the bolt. NOTE: A light tap to top of sensor prior to removal may reduce force needed for removal. 4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on the sensor case, and the O-ring may make removal difficult. INSTALLATION Notes: If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer from the sensor face completely, before attaching new spacer. If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new sensor (Fig. 5). 1. Inspect O-ring for damage, replace if necessary. 2. Ensure the O-ring is positioned in groove of the sensor, and apply a couple drops of clean engine oil to the O-ring prior to installing the sensor (Fig. 7). 3. Install sensor in the chain case cover and push sensor down until contact is made with the camshaft gear. 4. While holding the sensor in this position install and tighten the retaining bolt 14 Nm (125 in-lbs) torque. 5. Connect sensor electrical connector, and position connector away from the accessory belt 6. Install engine mount support bracket. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications NOTE: For information on how this type of sensor operates SEE, Powertrain Management/Computers and Control Systems/Coolant Temperature Sensor/Description and Operation. NOTE: Measure resistance using a high impedance Digital Volt Ohmmeter (DVOM). COLD CURVE (Reference voltage routed to sensor through PCM internal resistance of 10k ohm) Temperature ........................................................................................................................................ ........................................ Voltage -20° F ................................................................................................................................................... ....................................... 4.70 V -10° F ................................................................................................................................................... ....................................... 4.57 V 0° F ...................................................................................................................................................... ...................................... 4.45 V 10° F .................................................................................................................................................... ....................................... 4.30 V 20° F .................................................................................................................................................... ....................................... 4.10 V 30° F .................................................................................................................................................... ....................................... 3.90 V 40° F .................................................................................................................................................... ....................................... 3.60 V 50° F .................................................................................................................................................... ....................................... 3.30 V 60° F .................................................................................................................................................... ....................................... 3.00 V 70° F .................................................................................................................................................... ....................................... 2.75 V 80° F .................................................................................................................................................... ....................................... 2.44 V 90° F .................................................................................................................................................... ....................................... 2.15 V 100° F .................................................................................................................................................. ........................................ 1.83 V 110° F .................................................................................................................................................. ........................................ 1.57 V 120° F .................................................................................................................................................. ........................................ 1.25 V HOT CURVE (Reference voltage routed to sensor through PCM internal resistance of 10 k ohm) Temperature ........................................................................................................................................ ........................................ Voltage 110° F .................................................................................................................................................. ........................................ 4.20 V 120° F .................................................................................................................................................. ........................................ 4.00 V 130° F .................................................................................................................................................. ........................................ 3.77 V 140° F .................................................................................................................................................. ........................................ 3.60 V 150° F .................................................................................................................................................. ........................................ 3.40 V 160° F .................................................................................................................................................. ........................................ 3.20 V 170° F .................................................................................................................................................. ........................................ 3.02 V 180° F .................................................................................................................................................. ........................................ 2.80 V 190° F .................................................................................................................................................. ........................................ 2.60 V 200° F .................................................................................................................................................. ........................................ 2.40 V Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 2488 210° F .................................................................................................................................................. ........................................ 2.20 V 220° F .................................................................................................................................................. ........................................ 2.00 V 230° F .................................................................................................................................................. ........................................ 1.80 V 240° F .................................................................................................................................................. ........................................ 1.62 V 250° F .................................................................................................................................................. ........................................ 1.45 V Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 2489 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Crankshaft Position sensor screw .................................................................................................................................................... 12 Nm (105 in lbs) Camshaft Position sensor screw ...................................................................................................................................................... 12 Nm (105 in lbs) Coolant Sensor .......................................................................................................... .......................................................................... 7 Nm (60 in lbs) Ignition Coil .................................... ................................................................................................................................................ 12 Nm (105 in lbs) Ignition Switch ................................................................................................................... ................................................................. 2 Nm (17 in lbs) Spark Plugs ............................................. ........................................................................................................................................... 28 Nm (20 ft lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2490 Coolant Temperature Sensor/Switch (For Computer): Locations Ignition Coil And Coolant Temperature Sensor Location Sensor mounted under ignition coil. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2493 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2494 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2495 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2496 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2497 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2498 Coolant Sensor Circuit Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2499 Coolant Temperature Sensor/Switch (For Computer): Description and Operation LOCATION The Engine Coolant Temperature (ECT) sensor is threaded into the intake manifold, next to the thermostat housing. PURPOSE The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle speed, and ignition spark advance. OPERATION The sensor element extends into the coolant passage, where it maintains constant contact with the engine coolant. The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature increases, sensor resistance decreases.) The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below. As sensor resistance changes, the voltage drop across the sensor changes. The PCM translates the voltage drop across the sensor into engine coolant temperature. THEORY As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor (cold operation), or a 909 ohm resistor (warm operation). The resistance circuits are inside the PCM. For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the 10,000 ohm resistor. When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the 909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2500 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Coolant Temperature Sensor Resistance Test 1. With key off, disconnect connector from coolant temperature sensor. 2. Connect ohmmeter across coolant temperature sensor. Resistance should read as follows; - 700 to 1,000 Ohms at approximately 200°F (operating temperature). - 7,000 to 13,000 ohms at approximately 70°F, (room temperature). 3. If resistance is not within specifications, replace sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2501 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Ignition Coil And Coolant Temperature Sensor Location REMOVAL 1. Drain cooling system until coolant level is below sensor. 2. Disconnect coil pack electrical connector to sensor. 3. Remove coil mounting screws. 4. Rotate coil away from coolant temperature sensor. 5. Disconnect electrical connector from coolant temperature sensor. 6. Remove sensor from engine. INSTALLATION 1. Tighten the coolant sensor to 7 Nm (60 in lbs) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. 4. Install coil. Tighten coil mounting screws to 12 Nm (105 in lbs) torque. 5. Connect electrical connector to coil. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2506 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position sensor screw ................................................................................................................................................ 11.9 Nm (105 in lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Crank Position Sensor The Crankshaft Position Sensor is mounted on the transaxle bellhousing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 2509 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2512 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2513 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2514 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2515 Crankshaft Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2516 Crankshaft Position Sensor Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2517 Crankshaft Position Sensor: Electrical Diagrams Crankshaft Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2518 Crankshaft Position Sensor: Description and Operation LOCATION Mounted in transmission housing, above distance sensor. PURPOSE Powertrain Control Module (PCM) uses input to determine basic timing. OPERATION Crankshaft Sensor Driveplate Sensor reads a series of slots cut in transmission driveplate. NOTE: The distance between the sensor and torque converter drive plate is critical to system operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE COMPONENT REPLACEMENT AND REPAIR PROCEDURES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2519 Crankshaft Position Sensor: Service and Repair Fig. 5 Crankshaft Position Sensor Removal 1. Disconnect sensor electrical connector (Fig. 5). 2. Remove sensor retaining bolt. 3. Pull sensor straight up, and out of the transaxle housing. Installation Notes: If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer from the sensor face completely, before attaching new spacer. If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new sensor (Fig. 5). 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. 2. While holding the sensor in this position, install and tighten the retaining bolt to 11.9 Nm (105 in-lbs) torque. 3. Connect sensor electrical connector. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications Vacuum in Inches of Mercury MAP sensor Signal Voltage .39 in Hg .............................................................................................................................................. .............................. 4.90 V 3.34 in Hg ............................................................................................................................................ ............................... 4.60 V 6.30 in Hg ............................................................................................................................................ ............................... 3.60 V 9.25 in Hg ............................................................................................................................................ ............................... 3.10 V 12.20 in Hg .......................................................................................................................................... ................................ 2.60 V 15.15 in Hg .......................................................................................................................................... ................................ 2.10 V 18.11 in Hg .......................................................................................................................................... ................................ 1.60 V 21.06 in Hg .......................................................................................................................................... ................................ 1.10 V 24.01 in Hg .......................................................................................................................................... ................................ 0.60 V 26.97 in Hg .......................................................................................................................................... ................................ 0.31 V Condition ............................................................................................................................................. .................................. Expected Output Voltage High Vacuum (Idle/Deceleration) ............................................................................................................................................................. 0.5 to 1.5 volts Medium Vacuum (Cruise/Slight Acceleration) ......................................................................................................................................... 1.5 to 3.0 volts Low Vacuum (Hard Acceleration/Mechanical Failure) ............................................................................................................................. 3.0 to 4.5 volts NOTE: Any reading of 0 volts or over 5 volts indicates a problem in the MAP sensor circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations Manifold Pressure/Vacuum Sensor: Component Locations Engine Control Component Locations Back Side Of Intake Plenum View Sensor mounted on back side of intake plenum. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations > Page 2525 Back Side Of Intake Plenum View Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions Manifold Pressure/Vacuum Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2528 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2529 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2530 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2531 Manifold Pressure/Vacuum Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2532 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2533 MAP Sensor Circuit Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 2534 Manifold Pressure/Vacuum Sensor: Description and Operation LOCATION Sensor mounted on intake plenum. PURPOSE At start-up, the Powertrain Control Module (PCM) uses sensor to read barometric (atmospheric), pressure, for reference, to calculate air/fuel mixture. During operation the Powertrain Control Module (PCM) monitors sensor input to adjust spark advance and air/fuel mixture. OPERATION PCM supplies 5 volt sensor reference voltage. Sensor, connected to manifold vacuum at throttle body, converts intake manifold pressure into voltage. THEORY Sensor resistance and manifold absolute pressure are inversely proportional (as manifold absolute pressure increases, (low vacuum), sensor resistance decreases and vice versa). OUTPUT VOLTAGES Sensor output voltage range is 0.5 to 4.5 volts. - Output voltages between 0.5 and 1.5 volts indicate a high vacuum situation, such as idle or deceleration. - Output voltages between 1.5 and 3.0 volts indicate a medium level of vacuum such as a cruise or slight acceleration condition. - Output voltages between 3.0 and 4.5 volts indicate a low vacuum situation such as hard acceleration or a mechanical failure. - Any reading of 0 volts or over 5 volts indicates a problem. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 2535 Manifold Pressure/Vacuum Sensor: Testing and Inspection NOTE: To perform a complete test of the Manifold Absolute Pressure (MAP) sensor and its circuitry, refer to appropriate Diagnostic Chart. See: Computers and Control Systems/Testing and Inspection TO TEST THE MAP SENSOR ONLY: 1. Inspect the rubber nipple (fitting) from the MAP sensor to the throttle body. Repair as necessary. CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 2. Test the MAP sensor output voltage at the MAP sensor connector terminal 2. With the ignition switch ON, and the engine OFF. Output voltage should be 4 to 5 volts. 3. Test the MAP sensor output voltage at the MAP sensor connector terminal 2 at a hot, neutral idle speed condition. The voltage should drop to 1.5 to 2.1 volts. 4. Test PCM (terminal / pin-5) for the same voltage described above to verify the wire harness condition. Repair as necessary. 5. Test MAP sensor supply voltage at sensor connector terminal 3 with the ignition ON. The voltage should be approximately 5 volts (±O.5 V). 5 volts (±0.5 Volts). should also be present at terminal 6 of the PCM wire harness connector. Repair or replace the wire harness as necessary. 6. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM connector terminal / pin-4. Repair the wire harness if necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 2536 Manifold Pressure/Vacuum Sensor: Service and Repair MAP" Sensor Removal 1. Disconnect vacuum hose and electrical connector from sensor. 2. Remove sensor mounting screws and remove sensor. Installation 1. Install sensor and tighten screws. 2. Connect vacuum hose and electrical connector from sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Air/Fuel Oxygen Exhaust Ratio Sensor Voltage Gas Content 12.0:1 1.0 Volts [1] 5.0% CO [2] 13.0:1 0.85 Volts 3.8% CO [2] 14.0:1 0.65 Volts 1.3% CO [2] 14.7:1 0.45 Volts [5] 0.1% CO [2] 15.0:1 0.35 Volts 2.0% O2 [3] 16.0:1 0.25 Volts 3.0% O2 [3] 17.0:1 0.10 Volts [4] 4.0% O2 [3] Remarks [1] Full rich condition. [2] CO: Carbon monoxide, is a sign of incomplete ignition, (not enough oxygen to burn all the hydrocarbons in cylinder). [3] O2: Oxygen left over after all hydrocarbons have been burned. [4] Full lean condition. [5] Stoichiometric point: Output voltages below 0.45 volts indicate a lean condition, and output voltages over 0.45 volts indicate a rich condition. NOTE: Both lean and rich conditions are usually accompanied by high Hydrocarbon (HC) readings. Due to not enough fuel, (lean misses), or too much fuel, (not enough oxygen to burn all hydrocarbons). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations EGR Mounting Sensor threaded into exhaust manifold, just above flange. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2542 Back Side Of Intake Plenum View Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2545 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2546 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2547 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2548 Oxygen Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2549 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2550 Oxygen Sensor: Electrical Diagrams Oxygen Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2551 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2552 Oxygen Sensor: Description and Operation O2 Sensor Cutaway View (Typical) SENSOR PURPOSE Powertrain Control Module (PCM) uses input to determine whether to enrich or lean air/fuel mixture, during closed loop operation. SENSOR OPERATION The oxygen sensor generates a varying voltage signal dependent upon exhaust gas oxygen content at that point in the exhaust. - Oxygen sensor voltage signal is produced through a galvanic reaction within the sensors. Using the oxygen sensor voltage signal as an air/fuel ratio indicator the PCM can tell how well the system is responding to its output signals. - Changes in the sensor signal occur because the air/fuel ratio is constantly changing. - When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. - When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. Closed Loop During CLOSED LOOP operation, the PCM monitors the signals it receives from the oxygen sensor, and other sensors, and uses these signals to adjust the injector pulse width according to the current driving condition. Open Loop During OPEN LOOP operation, the PCM ignores the oxygen sensor's signals, and other sensor's signals, and adjusts injector pulse widths according to preprogrammed specifications in the PCM. HEATER PURPOSE Vehicle enters CLOSED LOOP faster, (because sensor reaches operating temperature sooner). Allows CLOSED LOOP operation during extended idle, (because heater maintains correct operating temperature). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test Oxygen Sensor: Testing and Inspection Powertrain Control Module Response Test Oxygen Sensor And Connector NOTE: This test should be performed only after the Oxygen Sensor (O2S) has passed the functional test and heating element test. NOTE: A four gas analyzer is needed to perform this test. NOTE: When performing this test it is important that no part of your body contact the vehicle body, as test results will be inaccurate. CAUTION: NEVER apply voltage directly to any computer sensor wire. PRECONDITIONING AND SET UP 1. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T), (to ensure vehicle and oxygen sensor are at operating temperature and vehicle is in closed loop). 2. Turn engine OFF, disconnect the oxygen sensor connector. Connect a jumper lead to the O2S signal wire. 3. Start the engine and run at 2,500 rpm for 1 minute, with the transmission in PARK (A/T), or NEUTRAL (M/T). 4. Let idle. LEAN MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO ENRICH MIXTURE) 1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery negative, hold for 10 to 20 seconds. - The CO and HC readings should increase, as the PCM opens the injectors for longer periods (longer pulse width), to enrich the mixture. 2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or engine control system will be necessary. SEE DIAGNOSIS BY SYMPTOM. RICH MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO LEAN OUT MIXTURE) 1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery positive, hold for 10 to 20 seconds. - The O2 readings should begin to increase, and the CO reading should decrease. 2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or engine control system will be necessary. SEE DIAGNOSIS BY SYMPTOM. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test > Page 2555 Oxygen Sensor: Testing and Inspection Sensor Functional Test Oxygen Sensor And Connector CAUTION: Use a high impedance [1] Digital Volt Ohm Meter (DVOM) ONLY, when testing components on computerized vehicles. 1. Make sure the vehicle is at normal operating temperature. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T). CAUTION: To avoid damaging sensor, voltmeter must be set in Volts mode only, (not ohms). 2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to read DC VOLTS. Disconnect the oxygen sensor ( O2S) electrical connector and connect the positive lead of the DVOM to the oxygen sensor signal wire. 3. Start engine. Create a lean condition for 10 seconds. Voltage should decrease to 0.2 volt or less and remain there. 4. Create a rich condition for 10 seconds. Voltage should increase to 0.8 volt or more and remain there. 5. If sensor fails to vary according to the test steps above, the sensor is defective. 6. Connect sensor and clear codes. Remarks: [1] Minimum 10 Meg (10,000,000) ohm input impedance. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test > Page 2556 Oxygen Sensor: Testing and Inspection Sensor Heating Element Test Oxygen Sensor And Connector Oxygen Sensor Connector Identification And PINOUT 1. Disconnect the Heated Oxygen Sensor (O2S), electrical connector from the wiring harness. 2. Set DVOM to read OHMS. Connect the ohmmeter between the heater feed and heater ground (terminals 3 and 4), of the sensor electrical connector. 3. Resistance should be between 5 and 7 ohms, if not replace the sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Page 2557 Oxygen Sensor: Service and Repair Oxygen Sensor Location (Typical) Oxygen Sensor Socket WARNING: Avoid physical contact with hot exhaust components. CAUTION: Do not pull on or cut sensor wires, when removing sensor. CAUTION: Use of excessive force may damage threads in exhaust manifold or pipe. REMOVAL 1. Disconnect oxygen sensor electrical connector. 2. Using a suitable tool (Snap-On socket YA8875, or equivalent), carefully remove the sensor from exhaust manifold or pipe. (Slightly tightening the sensor before removal may ease removal.) 3. Clean threads in exhaust manifold with an 18 mm X 1.5 + 6E tap. INSTALLATION 1. If a new sensor is being used, verify that the threads are coated with anti-seize compound, before installing in manifold or pipe. 2. If sensor is being reused, coat sensor threads with a nickel based anti-seize compound, (Loctite 771-64 or equivalent). CAUTION: Do not use graphite or other anti-seize compounds. 3. Install sensor, and tighten to 27 Nm (20 ft-lbs). 4. Connect wiring. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts Throttle Position Sensor: Customer Interest TPS - Harsh, Erratic, Or Delayed Transmission Shifts NO: 18-13-94 Rev. A GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Harsh, Erratic or Delayed Transmission Shifts THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 (AS) Caravan/Voyager/Town & Country 1994 (ES) Chrysler Voyager (Export Only) 1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX). SYMPTOM/CONDITION: Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold soak) and during warm-up. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or III) with the appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full range of travel, full open then full closed, and watch the voltage readings. The voltage change should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic voltage change or no voltage change during throttle movement in encountered, particularly when moving the throttle from wide open to closed throttle, proceed with the following repair.** PARTS REQUIRED: 1 4759001 Throttle Position Sensor REPAIR PROCEDURE: This bulletin involves replacing the throttle position sensor with a revised part. 1. Following the proper procedure, remove and replace the throttle position sensor using the new sensor, P/N 4759001. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-10-95 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts Throttle Position Sensor: All Technical Service Bulletins TPS - Harsh, Erratic, Or Delayed Transmission Shifts NO: 18-13-94 Rev. A GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Harsh, Erratic or Delayed Transmission Shifts THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 (AS) Caravan/Voyager/Town & Country 1994 (ES) Chrysler Voyager (Export Only) 1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX). SYMPTOM/CONDITION: Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold soak) and during warm-up. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or III) with the appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full range of travel, full open then full closed, and watch the voltage readings. The voltage change should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic voltage change or no voltage change during throttle movement in encountered, particularly when moving the throttle from wide open to closed throttle, proceed with the following repair.** PARTS REQUIRED: 1 4759001 Throttle Position Sensor REPAIR PROCEDURE: This bulletin involves replacing the throttle position sensor with a revised part. 1. Following the proper procedure, remove and replace the throttle position sensor using the new sensor, P/N 4759001. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-10-95 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2571 Throttle Position Sensor: Specifications THROTTLE POSITION .................................................................................................................................... INCREASE IN TPS VOLTAGE 10° Closed Throttle* ....................................................................................................................................................... 0 volts 20° ....................................................................................................................................................... ........... 0.38 volts 30° ....................................................................................................................................................... ........... 0.75 volts 45° Half Throttle ........................................................................................................................................................ 1.31 volts 58° ....................................................................................................................................................... ......... 1.80 volts** 75° ....................................................................................................................................................... ........ 2.43 volts*** 90° Wide Open Throttle .................................................................................................................................................. 3.00 volts * At idle position the throttle blade is open 10°. The throttle blade is rotated 80° when the throttle is moved from the idle position to the "wide open" position, . ** The PCM recognizes a TPS voltage rise of 1.80 volts or more over idle position voltage as "Wide Open Throttle" (WOT). *** If the TPS voltage sensed at the PCM rises 2.43 volts or more above idle position voltage, the PCM shuts off fuel injection. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Throttle Body View With Idle Air Control Motor Idle Air Control Motor And Throttle Position Sensor Mounted on throttle body. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 2574 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2577 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2578 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2579 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2580 Throttle Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2581 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2582 Throttle Position Sensor: Electrical Diagrams Throttle Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 2583 Throttle Position Sensor: Description and Operation PURPOSE PCM uses sensor input with other inputs to determine current operating conditions. PCM adjusts air/fuel mixture (injector pulse width) and ignition timing. OPERATION PCM supplies 5 volt sensor reference voltage. Sensor is a variable resistor (potentiometer), whose resistance is dependent on the angle of the throttle blade (or throttle opening). Output voltage ranges from approximately 0.5 Volts, (at idle position), to approximately 4.0 Volts, (at Wide Open Throttle). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 2584 Throttle Position Sensor: Testing and Inspection NOTE: The following procedure tests the TPS only. To perform a complete test of the TPS and its circuitry, SEE Computers and Control Systems/Testing and Inspection/Procedures/Diagnostic Charts/Introduction. PROCEDURE 1. The TPS can be tested with a digital voltmeter. The center terminal of the TPS is the output terminal. 2. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed), and at Wide Open Throttle (WOT). - At idle, TPS output voltage should be approximately 0.5 to 1.0 volt. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. - At wide open throttle, TPS output should be approximately 3.5 volts. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 2585 Throttle Position Sensor: Adjustments PROCEDURE - The Throttle Position Sensor on this vehicle is fixed and adjustment is not required. - If sensor output voltage is outside acceptable range, sensor should be replaced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 2586 Throttle Position Sensor: Service and Repair Throttle Position Sensor (TPS)/Automatic Idle Speed (AIS) Motor Throttle Position Sensor Removed Removal 1. Disconnect the negative battery cable. 2. Disconnect the Throttle Position Sensor (TPS) wiring connector. 3. Remove the mounting screws (2), and remove the TPS from the throttle shaft. Installation 1. Install the new TPS on the throttle shaft and install screws, torqueing them to 17 in-lbs (2 Nm). 2. Connect the TPS wiring connector. 3. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2595 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2596 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2597 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 2603 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 2604 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2609 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2610 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2611 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 2617 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 2618 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 2621 Park Neutral Position Switch / PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 2622 Transmission Position Switch/Sensor: Locations 4 Speed A/T Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 2625 Park / Neutral Position Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 2628 Transmission Position Switch/Sensor: Description and Operation Switch, Transmission Range The white Transmission Range Switch (formerly called PRNDL) is used as an input to the Transmission Control Module, on the 4 speed electronic automatic transaxle. Note: The Transmission Range Sensor is a different component from the Transmission Range Switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 2631 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 2632 Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations Vehicle Speed Sensor: Component Locations This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates vehicle speed based on input received from Input and Output speed sensor mounted on the transaxle. Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 2637 Vehicle Speed Sensor: Connector Locations This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates vehicle speed based on input received from Input and Output speed sensor mounted on the transaxle. Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2640 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2641 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2642 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2643 Vehicle Speed Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2644 Vehicle Speed Sensor: Electrical Diagrams Vehicle Speed Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2645 Vehicle Speed Sensor: Description and Operation This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates vehicle speed based on input received from Input and Output speed sensor mounted on the transaxle. Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts Throttle Position Sensor: Customer Interest TPS - Harsh, Erratic, Or Delayed Transmission Shifts NO: 18-13-94 Rev. A GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Harsh, Erratic or Delayed Transmission Shifts THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 (AS) Caravan/Voyager/Town & Country 1994 (ES) Chrysler Voyager (Export Only) 1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX). SYMPTOM/CONDITION: Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold soak) and during warm-up. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or III) with the appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full range of travel, full open then full closed, and watch the voltage readings. The voltage change should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic voltage change or no voltage change during throttle movement in encountered, particularly when moving the throttle from wide open to closed throttle, proceed with the following repair.** PARTS REQUIRED: 1 4759001 Throttle Position Sensor REPAIR PROCEDURE: This bulletin involves replacing the throttle position sensor with a revised part. 1. Following the proper procedure, remove and replace the throttle position sensor using the new sensor, P/N 4759001. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-10-95 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts Throttle Position Sensor: All Technical Service Bulletins TPS - Harsh, Erratic, Or Delayed Transmission Shifts NO: 18-13-94 Rev. A GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Harsh, Erratic or Delayed Transmission Shifts THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 (AS) Caravan/Voyager/Town & Country 1994 (ES) Chrysler Voyager (Export Only) 1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX). SYMPTOM/CONDITION: Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold soak) and during warm-up. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or III) with the appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full range of travel, full open then full closed, and watch the voltage readings. The voltage change should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic voltage change or no voltage change during throttle movement in encountered, particularly when moving the throttle from wide open to closed throttle, proceed with the following repair.** PARTS REQUIRED: 1 4759001 Throttle Position Sensor REPAIR PROCEDURE: This bulletin involves replacing the throttle position sensor with a revised part. 1. Following the proper procedure, remove and replace the throttle position sensor using the new sensor, P/N 4759001. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-10-95 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2660 Throttle Position Sensor: Specifications THROTTLE POSITION .................................................................................................................................... INCREASE IN TPS VOLTAGE 10° Closed Throttle* ....................................................................................................................................................... 0 volts 20° ....................................................................................................................................................... ........... 0.38 volts 30° ....................................................................................................................................................... ........... 0.75 volts 45° Half Throttle ........................................................................................................................................................ 1.31 volts 58° ....................................................................................................................................................... ......... 1.80 volts** 75° ....................................................................................................................................................... ........ 2.43 volts*** 90° Wide Open Throttle .................................................................................................................................................. 3.00 volts * At idle position the throttle blade is open 10°. The throttle blade is rotated 80° when the throttle is moved from the idle position to the "wide open" position, . ** The PCM recognizes a TPS voltage rise of 1.80 volts or more over idle position voltage as "Wide Open Throttle" (WOT). *** If the TPS voltage sensed at the PCM rises 2.43 volts or more above idle position voltage, the PCM shuts off fuel injection. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Throttle Body View With Idle Air Control Motor Idle Air Control Motor And Throttle Position Sensor Mounted on throttle body. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 2663 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2666 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2667 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2668 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2669 Throttle Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2670 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2671 Throttle Position Sensor: Electrical Diagrams Throttle Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 2672 Throttle Position Sensor: Description and Operation PURPOSE PCM uses sensor input with other inputs to determine current operating conditions. PCM adjusts air/fuel mixture (injector pulse width) and ignition timing. OPERATION PCM supplies 5 volt sensor reference voltage. Sensor is a variable resistor (potentiometer), whose resistance is dependent on the angle of the throttle blade (or throttle opening). Output voltage ranges from approximately 0.5 Volts, (at idle position), to approximately 4.0 Volts, (at Wide Open Throttle). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 2673 Throttle Position Sensor: Testing and Inspection NOTE: The following procedure tests the TPS only. To perform a complete test of the TPS and its circuitry, SEE Computers and Control Systems/Testing and Inspection/Procedures/Diagnostic Charts/Introduction. PROCEDURE 1. The TPS can be tested with a digital voltmeter. The center terminal of the TPS is the output terminal. 2. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed), and at Wide Open Throttle (WOT). - At idle, TPS output voltage should be approximately 0.5 to 1.0 volt. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. - At wide open throttle, TPS output should be approximately 3.5 volts. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 2674 Throttle Position Sensor: Adjustments PROCEDURE - The Throttle Position Sensor on this vehicle is fixed and adjustment is not required. - If sensor output voltage is outside acceptable range, sensor should be replaced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 2675 Throttle Position Sensor: Service and Repair Throttle Position Sensor (TPS)/Automatic Idle Speed (AIS) Motor Throttle Position Sensor Removed Removal 1. Disconnect the negative battery cable. 2. Disconnect the Throttle Position Sensor (TPS) wiring connector. 3. Remove the mounting screws (2), and remove the TPS from the throttle shaft. Installation 1. Install the new TPS on the throttle shaft and install screws, torqueing them to 17 in-lbs (2 Nm). 2. Connect the TPS wiring connector. 3. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2681 Camshaft Position Sensor: Mechanical Specifications Camshaft Position sensor screw ..................................................................................................................................................... 14 Nm (125 in lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor Location The Camshaft Position (CMP) sensor is located on the timing gear cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 2684 Camshaft Position Sensor Location Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2687 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2688 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2689 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2690 Camshaft Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2691 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2692 Camshaft Position Sensor: Electrical Diagrams Camshaft Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2693 Camshaft Position Sensor: Description and Operation Camshaft Sensor PURPOSE - Sensor provides PCM with cylinder identification. - PCM uses sensor input to determine fuel injection sequence and ignition timing. OPERATION Sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). - When a notch aligns with the sensor, voltage spikes high (5.0 volts). - As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. - The number of notches determine the amount of pulses. NOTE: If available, an oscilloscope can display the square wave patterns of each timing event. NOTE: The arrows and cylinder call outs on the following image represent which cylinder the flat spot and notches identify, they do not indicate Top Dead Center (TDC) position. Camshaft Sprocket - When the PCM receives two cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder # 1 are next (on driveplate). - When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number # 2 crankshaft timing marks are next. - After 3 camshaft pulses, the PCM knows cylinder # 4 crankshaft timing marks follow. - One camshaft pulse after the three pulses indicates cylinder # 5. - The two camshaft pulses after cylinder 5 signals cylinder # 6. - The PCM can synchronize on cylinders 1 or 4. NOTE: TDC does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. NOTE: The distance between the sensor and camshaft sprocket is critical to system operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE Powertrain Management/Computers and Control Systems/Camshaft Position Sensor/Service and Repair. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2694 Camshaft Position Sensor: Service and Repair Fig. 7 Camshaft Position Sensor REMOVAL 1. Disconnect sensor electrical connector (Fig. 7). 2. Remove engine mount support bracket. 3. Loosen camshaft position sensor retaining bolt enough to allow slot in sensor to slide past the bolt. NOTE: A light tap to top of sensor prior to removal may reduce force needed for removal. 4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on the sensor case, and the O-ring may make removal difficult. INSTALLATION Notes: If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer from the sensor face completely, before attaching new spacer. If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new sensor (Fig. 5). 1. Inspect O-ring for damage, replace if necessary. 2. Ensure the O-ring is positioned in groove of the sensor, and apply a couple drops of clean engine oil to the O-ring prior to installing the sensor (Fig. 7). 3. Install sensor in the chain case cover and push sensor down until contact is made with the camshaft gear. 4. While holding the sensor in this position install and tighten the retaining bolt 14 Nm (125 in-lbs) torque. 5. Connect sensor electrical connector, and position connector away from the accessory belt 6. Install engine mount support bracket. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2699 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position sensor screw ................................................................................................................................................ 11.9 Nm (105 in lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Crank Position Sensor The Crankshaft Position Sensor is mounted on the transaxle bellhousing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 2702 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2705 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2706 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2707 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2708 Crankshaft Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2709 Crankshaft Position Sensor Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2710 Crankshaft Position Sensor: Electrical Diagrams Crankshaft Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2711 Crankshaft Position Sensor: Description and Operation LOCATION Mounted in transmission housing, above distance sensor. PURPOSE Powertrain Control Module (PCM) uses input to determine basic timing. OPERATION Crankshaft Sensor Driveplate Sensor reads a series of slots cut in transmission driveplate. NOTE: The distance between the sensor and torque converter drive plate is critical to system operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE COMPONENT REPLACEMENT AND REPAIR PROCEDURES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2712 Crankshaft Position Sensor: Service and Repair Fig. 5 Crankshaft Position Sensor Removal 1. Disconnect sensor electrical connector (Fig. 5). 2. Remove sensor retaining bolt. 3. Pull sensor straight up, and out of the transaxle housing. Installation Notes: If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer from the sensor face completely, before attaching new spacer. If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new sensor (Fig. 5). 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. 2. While holding the sensor in this position, install and tighten the retaining bolt to 11.9 Nm (105 in-lbs) torque. 3. Connect sensor electrical connector. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition - Tamper Resistant Ignition Cylinder Addition NUMBER: 23-44-94D GROUP: Body DATE: Jun. 3, 1994 Models: 1994 Town & Country, Caravan, Voyager - Publication No. 81-370-4105 DISCUSSION: A new method of ignition key cylinder retention is used on the subject vehicles for improved vehicle security. The ignition key cylinder retaining pin has been replaced with a tamper resistant screw and a bracket, refer to the illustration. A Snap-On TTXR20A2 torx-bit or equivalent is required to remove the screw. The 1995 Dakota service manual was completed prior to this information being available to Service Publications. The vehicles listed as 1994 models only, will have this information already in their corresponding 1995 service manual. DESCRIPTION OF CHANGES Add Tamper Resistant Ignition Key Cylinder Info. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 2718 8D - 37 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 2719 8D - 38 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 2720 8D - 39 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 2721 8D - 39A Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations Fig 1 Intake Plenum Mounting Bolts Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications Air/Fuel Mixture: Specifications The Air/Fuel Ratio is controlled by the Powertrain Control Module (PCM) and is not adjustable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications > Page 2730 Air/Fuel Mixture: Adjustments CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle mixture using this screw! Idle mixture is electronically controlled by the Powertrain Control Module (PCM), and is not adjustable. If an idle mixture problem is suspected, check oxygen sensor and feedback system. SEE Computers and Control Systems. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications NOTE: Idle speed is not adjustable. Powertrain Control Module (PCM) controls idle speed through Idle Air Control (IAC) Motor. If idle speed is outside of specifications, or is rough, or unstable, inspect and clean throttle body, (if deposits are visible). After cleaning throttle body perform minimum air flow test. SEE DIAGNOSIS, TESTING AND INSPECTION PROCEDURES MINIMUM AIRFLOW TEST IDLE SPEED ODOMETER READING IDLE SPEED Less than 1000 miles 525-875 RPM More than 1000 miles 575-875 RPM Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2734 Idle Speed: Adjustments CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle speed using this screw, unless directed to do so in a service procedure. Idle speed is electronically controlled by the Powertrain Control Module (PCM) through the Idle Air Control (IAC) motor, and is not adjustable. If idle is outside of specified RPM, or is rough, or unstable, inspect and clean throttle body if deposits are visible. Perform Minimum Idle Air Flow Test if applicable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fig 1 Intake Plenum Mounting Bolts Fuel Pressure Release Procedure - Typical WARNING: The fuel system is under constant pressure of approximately 48 psi (330 kPa), even when the engine is OFF. 1. Disconnect negative battery cable. 2. Loosen fuel tank filler cap to relieve fuel tank pressure. 3. Remove cap on fuel rail pressure test port (Fig. 1). 4. Place one end of fuel pressure release hose, tool C-4799-1 (or equivalent), in an approved gasoline container. Connect the other end of this hose to the fuel rail service port. Fuel pressure should bleed off into container. 5. Perform necessary fuel system service procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications 3.3L, 3.8L Except Code T Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations 3.3L, 3.8L Except Code T Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations This vehicle is not equipped with timing marks. However spark advance can be monitored using a DRBII or equivalent scan tool. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T Harsh Shift At Low Speed/Speedo. Fluctuates Ignition Cable: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T Harsh Shift At Low Speed/Speedo. Fluctuates > Page 2757 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T Harsh Shift At Low Speed/Speedo. Fluctuates > Page 2758 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Ignition Cable: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 2764 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 2765 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2766 Ignition Cable: Specifications Minimum ..................................................................................................................................................... 250 ohms per inch (3,000 ohms per foot) Maximum ............................................................................................................................................... 1,000 ohms per inch (12,000 ohms per foot) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2767 Ignition Cable: Description and Operation NOTE: Spark Plug cables are sometimes referred to as "secondary ignition wires". Purpose Transfer electrical current from the distributor to individual spark plugs at each cylinder. Resistance type cables are used to suppress Radio Frequency Interference (RFI), from the ignition system. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Ignition Cable: Initial Inspection and Diagnostic Overview INSPECTION Check the high-tension cable connections for good contact at the ignition coil, distributor cap towers and spark plugs. Terminals should be fully seated. The terminals and covers should be in good condition. Terminals should fit tightly to the ignition coil, distributor cap, and spark plugs. The cover (boot) of the cable should fit tight at the coil tower, distributor tower or spark plug insulator. NOTE: Loose cable connections can cause corrosion and increase resistance resulting in shorter cable service life. To maintain proper sealing at terminal connections, do not disconnect cables. This should only be done when testing. Clean high tension cables with a cloth moistened with a nonflammable solvent and wipe dry. Check for brittle or cracked insulation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2770 Ignition Cable: Component Tests and General Diagnostics Secondary Ignition Cable Insulation Test CAUTION: Do not pull spark plug cables from distributor cap of four cylinder engines. The cables must be released from inside the distributor cap. CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during testing. Excessive heat could damage the catalytic converter. Total test time must not exceed ten minutes. CAUTION: To maintain proper sealing at the terminal connections, the connections should not be broken unless testing indicates high resistance, an open circuit or other damage. INSPECTION Check connections at the coil, distributor cap towers and spark plugs. Terminals should be fully seated, and the nipples and spark plug covers should be in good condition. Covers should fit tightly on the coil, distributor cap towers and spark plug insulators. Cable connections that are loose will corrode and increase the resistance and permit water to enter the towers causing ignition malfunction. INSULATION TEST NOTE: When testing secondary cables for punctures and cracks with an oscilloscope follow the equipment manufacturers instructions. If an oscilloscope is not available, secondary cables can be tested as follows: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. 2. With engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. Check the coil cable the same way. 3. Replace ALL cracked, leaking or faulty cables. RESISTANCE TEST Use an ohmmeter to check resistance type cable for open circuits, loose terminals or high resistance as follows: Remove cable from spark plug. Lift distributor cap from distributor with cables intact. Do not remove cables from cap. The cables must be removed from the spark plugs. Connect the ohmmeter between spark plug end terminal and the corresponding electrode inside the cap, make sure ohmmeter probes arc in good contact. Resistance should be within tolerance shown in the cable resistance chart. If resistance is not within tolerance, remove cable at cap tower and check the cable. If resistance is still not within tolerance, replace cable assembly. Test all spark plug cables in same manner. To test coil to distributor cap high tension cable, remove distributor cap with the cable intact. Do not remove cable from the cap. Connect the ohmmeter between center contact in the cap and remove the cable at coil tower and check cable resistance. If resistance is not within tolerance, replace the cable. Also, check for a loose connection at the tower or for a faulty coil. Inspect coil tower for cracks or carbon tracking. Secondary Ignition Cable Resistance Test CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during testing. Excessive heat could damage the catalytic converter. Total test time must not exceed ten minutes. CAUTION: To maintain proper sealing at the terminal connections, the connections should not be broken unless testing indicates high resistance, an open circuit or other damage. NOTE: Use an ohmmeter to check resistance type cable for open circuits, loose terminals or high resistance as follows: SPARK PLUG CABLES 1. Remove cable from spark plug. 2. Lift distributor cap from distributor with cables intact. Do not remove cables from cap. The cables must be removed from the spark plugs. 3. Connect the ohmmeter between spark plug end terminal and the corresponding electrode inside the cap, ensure probes make good contact. Resistance should be within tolerance. 4. If the resistance is not within tolerance, remove cable at cap tower and check the cable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2771 5. If resistance is still not within tolerance, replace cable assembly. 6. Test all spark plug cables in same manner. COIL TO DISTRIBUTOR HIGH TENSION CABLE 1. Remove distributor cap with the cable intact. Do not remove cable from the cap. 2. Remove the cable at coil tower 3. Connect the ohmmeter between center contact in the cap and the coil end of cable. 4. If resistance is not within tolerance, replace the cable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications Spark Plug: Specifications Gap Specifications NOTE: Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Spark Plug Gap ................................................................................................................................... ............................... 1.2 to 1.3 mm (0.048 to 0.053 in) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications > Page 2776 Spark Plug: Specifications Tightening Specifications Spark Plug Torque ............................................................................................................................... ....................................................... 28 Nm (20 ft-lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2777 Spark Plug: Description and Operation Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for spark plug diagnosis. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator NOTE: Replace any spark plugs which have cracked broken or chipped insulators. Symptoms: Insulator chipped or broken. Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap. - Severe detonation also can separate the insulator from the center electrode. - Sudden Rise In Tip Temperature. - Severe Operating Conditions. - Improper Gapping Of Plugs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2780 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2781 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Symptoms: Dry, black deposits on the electrodes. Possible Causes: - On one or two plugs, may be caused by sticking valves or defective spark plug cables. - On the entire set, may be caused by a clogged air cleaner. - Poor Ignition Output NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs do not reach a high enough operating temperature during short operating periods to burn fuel completely. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2782 Spark Plug: Testing and Inspection Electrode Gap Bridging Electrode Gap Bridging Symptoms: Gap between the electrodes bridged by deposits. Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the electrodes. NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2783 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator NOTE: Replace any spark plugs which have cracked broken or chipped insulators. Symptoms: Insulator chipped or broken. Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap. - Severe detonation also can separate the insulator from the center electrode. - Sudden Rise In Tip Temperature. - Severe Operating Conditions. - Improper Gapping Of Plugs. Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Symptoms: Dry, black deposits on the electrodes. Possible Causes: - On one or two plugs, may be caused by sticking valves or defective spark plug cables. - On the entire set, may be caused by a clogged air cleaner. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2784 - Poor Ignition Output NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs do not reach a high enough operating temperature during short operating periods to burn fuel completely. Electrode Gap Bridging Electrode Gap Bridging Symptoms: Gap between the electrodes bridged by deposits. Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the electrodes. NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures. Heavy Colored Deposits DESCRIPTION: Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on the side facing the intake valve. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap, and reinstall .............................................................................................................................................................. .................................................................................... Oil or Ash Encrusted Oil Or Ash Encrusted Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2785 Symptoms: Electrodes encrusted with dry oil or ash. Possible Causes: One or more plugs, evaluate the cause of oil entry into the combustion chamber. Premature Electrode Wear - Preignition Damage Preignition Damage Symptoms: Center electrode dissolves first and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Possible Causes: Excessive combustion chamber temperature. - Incorrect spark plug heat range [1]. - Ignition timing is over advanced - Other operating conditions are causing engine overheating. [1] Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Red, Brown, Yellow or White Deposits - Fuel Additives Scavenger Deposits Symptoms: Red, Brown, White or Yellow deposits. Possible Causes: Normal condition caused by certain fuel additives which are designed to change the nature of deposits and decrease spark plug misfire tendencies. NOTE: Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and be cleaned using standard procedures. Shiny Yellow Glaze DESCRIPTION: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2786 Shiny yellow glaze coating on the insulator. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Metal By-products Of Combustion - Avoid sudden acceleration with wide open throttle after long periods of low speed driving. .............................................................................................................................................................. .................................................................................... Spark Plug Inspection PROCEDURE - Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance Schedules. - Spark plugs that have low mileage may be cleaned and reused if not otherwise defective. Refer to the Spark Plug Condition of this section. After cleaning, file the center electrode flat with a small point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The spark plug gap is 0.89 mm (0.035 in). - Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Spark Plug Resistance Test Resistance should be at least 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Wet Oily Deposits Symptoms: Electrodes coated with excessive wet fuel or oil. Possible Causes: In older engines, wet fouling can be caused by worn rings or excessive cylinder wear. - In new or recently overhauled engines, fouling may occur before normal oil control is achieved. Break-in fouled spark plugs can be usually be cleaned and installed. White or Gray - Burned or Blistered Insulator Spark Plug Overheating Symptoms: White or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in per 1000 miles of operation. Possible Causes: Plug(s) with wrong heat range. - Over advanced ignition timing. - Detonation - Cooling system malfunction - Check for lean air-fuel mixture - Check the torque value of the plugs to ensure good plug-engine seat contact Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2787 Spark Plug: Adjustments Setting Spark Plug Electrode Gap Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground -- center electrode. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Replacement Notes Spark Plug: Service and Repair Replacement Notes TIP: Always keep plugs in the order they were removed. Any plug that looks different from other plugs indicates a problem in that cylinder. NOTE: For further diagnosis by spark plug condition SEE Ignition System/Spark Plug/Testing and Inspection/Procedures Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Replacement Notes > Page 2790 Spark Plug: Service and Repair Removal and Installation CAUTION: Note routing of secondary ignition cables before removing. Failure to route cables properly may result in radio interference, ignition cross fire, or ignition short to ground. NOTE: Keep plugs in order removed. A plug, that looks different from the rest, could be a problem indicator. REMOVAL 1. Spray compressed air around spark plug to prevent foreign material from entering combustion chamber. 2. Remove spark plug wire by grasping boot and turning 1/2 turn while pulling boot back in a steady motion. 3. Remove spark plug using socket with foam insert. INSPECT FOR: - Color of Deposits - Excessive Deposits - Electrode wear - Cracked or Damaged Threads Or Insulator - Worn or Bent Electrodes - Damaged Gasket INSTALLATION 1. Start plug in cylinder head by hand, to prevent cross threading. CAUTION: Do not overtighten plugs, overtightening can distort plugs resulting in a changed gap. 2. Torque spark plugs to 20 ft-lbs (28 Nm). 3. Install secondary ignition cables on spark plugs, (be sure connectors are pushed onto plug completely). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Cylinder Compression Pressure 100 psi NOTE: No more than 25% variance between cylinders. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2794 Compression Check: Service Precautions COMPRESSION TESTING When performing a compression test, remove the fuel pump relay fuse and disconnect power to the ignition. This will stop fuel flow to the injectors and prevent engine from starting. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2795 Compression Check: Testing and Inspection PROCEDURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire (Conventional Ignition System). For Direct Ignition System (DIS) disconnect the coil connector. 5 . Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adaptor into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is reached on gage. Record this pressure as #1 cylinder pressure. 7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 9. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. 11. Clean or replace spark plugs as necessary and adjust gap. Tighten to specifications. 12. Test resistance of spark plug cables. Perform secondary circuit inspection. 13. Test coil output voltage, primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at idle and different RPM ranges. 15. The air filter elements should be replaced as specified. 16. Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt drives. 18. Road test vehicle as a final test. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments This engine uses hydraulic lash adjusters, no adjustment is necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation A/C Signal: Description and Operation PURPOSE Powertrain Control Module (PCM) monitors engine load and A/C system pressure, and cycles the A/C compressor clutch accordingly. CONDITIONS A/C or Defrost switch ON. Combination valve, A/C low pressure and high pressure switches are closed. OPERATION Powertrain Control Module (PCM) receives an A/C selected signal. - PCM engages A/C compressor clutch (by grounding clutch relay). - PCM cycles compressor clutch depending on engine load and A/C system pressure. - PCM maintains correct engine idle speed, through the Idle Air Control (IAC) Motor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Idle Air Control Motor - Whistling Noise Auxiliary Air Valve (Idle Speed): Technical Service Bulletins Idle Air Control Motor - Whistling Noise NO.: 14-09-93 Rev.A GROUP: Fuel DATE: Nov. 12, 1993 SUBJECT: Idle Air Control Motor Whistle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NO. 14-09-93 DATED 6-4-93, WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. CHANGES INCLUDE MODELS & DIAGNOSIS REVISION. MODELS: ** 1991 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon (AY) Imperial/New Yorker Fifth Avenue 1991 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country** 1993 (LH) Concorde/Intrepid/Vision 1994 (LH) LHS/New Yorker **NOTE: THIS BULLETIN APPLIES TO 3.3L & 3.8L AC & AY; 3.3L AS BUILT PRIOR TO MDH 1108XX; AND LH MODELS BUILT PRIOR TO MDH 0726XX.** SYMPTOM/CONDITION: Vehicle exhibits a high-pitched whistling noise from the engine compartment at idle. The noise may be more prevalent when the engine is under a load such as air conditioning or headlamps on. No whistling can be heard while cruising. DIAGNOSIS: **Place the gear selector in park, set the parking brake, and start the engine. Let the engine idle for several minutes (3 to 5 minutes). Verify there are no vacuum leaks in the engine compartment. Increase the engine RPM's to around 1200 using the throttle. If the whistle sound goes away, perform the repair procedure below. If the whistle does not go away see Technical Service Bulletin No. 21-01-93 published 1-13-93.** PARTS REQUIRED: 1 4612673 Idle Air Control Motor REPAIR PROCEDURE: This bulletin involves the replacement of the idle air control motor. 1. Using the procedures outlined in the appropriate Service Manual, replace the idle air control motor. 2. Run the engine at idle to verify the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 14-30-23-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly Body Controller: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 2815 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly Body Controller: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 2821 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > Page 2822 Body Control Module System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Body Controller: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2825 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2826 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2827 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2828 Body Controller: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2829 Body Controller: Connector Views Body Control Module Blue Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2830 Body Control Module Natural Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2831 BCM Natural Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2832 BCM Blue Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and ID > BCM Identification Body Controller: Application and ID BCM Identification There are two different body control modules available on these vehicles; One supports the mechanical instrument cluster as well as the electro/mechanical instrument cluster. - The other supports the electronic instrument cluster. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and ID > BCM Identification > Page 2835 Body Controller: Application and ID Glossary of Terms BCM - Body Control Module CCD - Chrysler Collision Detection (Vehicle Communications Bus) CMTC - Compass/mini-trip Computer (module) DLC - Data Link Connector (previously Called "Diagnostic Connector") DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument Cluster ET - Elapsed Time IOD - Ignition Off Draw MET - Metric MIC - Mechanical Instrument Cluster ODO - Odometer PCM - Powertrain Control Module PDC - Power Distribution Center RKE Remote Keyless Entry Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and ID > Page 2836 Body Controller: Description and Operation PURPOSE The body control module: Provides power or ground for a variety of systems and uses a voltage drop to monitor these systems. - Is the only module that has the capability of providing both bias and termination on the CCD bus system. - Is used to store odometer information displayed in the electronic instrument cluster. OPERATION The body systems are monitored by individual control modules, which send information about their operation to the body control module over the CCD (Chrysler Collision Detection multiplex system) bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed to the appropriate module(s). - Each module receives the same information about a component or circuit as another module does. - This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. BODY SYSTEM COVERAGE: - Automatic Door Locks - Compass/mini-trip Module - Courtesy Lamps - Electronic Instrument Cluster (EIC) - Electro/mechanical Instrument Cluster - Mechanical Instrument Cluster (MIC) - Illuminated Entry - Remote Keyless Entry (RKE) - Intermittent Wipers - Liftgate Release NOTE: Communication over the CCD bus is essential to the proper operation of vehicle on-board diagnostic systems and scan tool communication. Bus or scan tool problems must be corrected before proceeding with diagnostic testing. If there is a problem, refer to Vehicle Communications (CCD) Bus/Testing and Inspection for diagnosis and repair procedures. TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is not set or if it is set incorrectly, any speed-related accessories will not operate or will operate inaccurately. - This includes the speedometer, speed control, rolling door locks, and other devices that are operated by the powertrain and body controllers. - For instructions on setting the pinion factor, see the appropriate transmission section. GLOSSARY OF TERMS BCM - Body Control Module CCD - Chrysler Collision Detection (vehicle Communications Bus) CMTC - Compass/mini-trip Computer (module) DLC - Data Link Connector (previously Called "diagnostic Connector") DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument Cluster ET - Elapsed Time IOD - Ignition Off Draw MET - Metric MIC - Mechanical Instrument Cluster ODO - Odometer PCM - Powertrain Control Module PDC - Power Distribution Center RKE Remote Keyless Entry Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Controller: Component Tests and General Diagnostics Diagnostic Notes - Read First TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is not set or if it is set incorrectly, any speed-related accessories will not operate or will operate inaccurately. - This includes the speedometer, speed control, rolling door locks, and other devices that are operated by the powertrain and body controllers. - For instructions on setting the pinion factor, see the appropriate transmission section. NOTE: These diagnostics are based on the failure condition or symptom being present at the time of diagnosis. TIPS: Verify that the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Be careful when performing electrical tests to prevent accidental shorting of terminals. Such mistakes can damage fuses or components and will sometimes set a second code, making diagnosis of the original problem more difficult. WARNINGS: - When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as watchbands or bracelets that might make an inadvertent electrical contact. - When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests. To efficiently diagnose CCD bus problems follow these six steps: 1. Verify Complaint 2. Check for Related Symptoms 3. Analyze Symptoms 4. Isolate the Problem 5. Repair the Isolated Problem 6. Verify Proper Operation ROAD TESTING Some complaints will require a test drive to duplicate the diagnostic code or symptom condition and to verify the repair. CAUTIONS: Before road testing a vehicle, be sure that all components are reassembled. - During the test drive, do not try to read the scan tool screen while in motion. - Do not hang the scan tool from the rear view mirror or operate it yourself. Have an assistant available to operate the scan tool. TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is not set or if it is set incorrectly, any speed-related accessories will not operate or will operate inaccurately. - This includes the speedometer, speed control, rolling door locks, and other devices that are operated by the powertrain and body controllers. - For instructions on setting the pinion factor, see the appropriate transmission section. Description of On-Board Diagnostics A scan tool is required to read body system trouble codes. However, not all body system problems have a corresponding trouble code. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2839 Body Controller: Scan Tool Testing and Procedures If the scan tool Does Not Power Up; Check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). If all connections are proper between scan tool and the vehicle, and the vehicle battery is fully charged, an inoperative scan tool may be the result or faulty cable or vehicle wiring. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and Inspection > Page 2840 Body Controller: Tools and Equipment The following tools are recommended to properly diagnose CCD bus problems: - Scan tool -- with correct cartridge and applicable connectors. - Jumper Wires - Ohmmeter - Oil Pressure Gauge - Voltmeter Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Description and Operation Brake Signal: Description and Operation LOCATION Sensor mounted on brake pedal support bracket. PURPOSE Powertrain Control Module (PCM) uses switch input to control idle speed and speed control. OPERATION PCM vents speed control system vacuum and turns speed control system OFF when appraised of a brake switch actuation. PCM prevents engine stall during rapid decel, by actuating Idle Air Control (IAC) motor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2848 Camshaft Position Sensor: Mechanical Specifications Camshaft Position sensor screw ..................................................................................................................................................... 14 Nm (125 in lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor Location The Camshaft Position (CMP) sensor is located on the timing gear cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 2851 Camshaft Position Sensor Location Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2854 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2855 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2856 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2857 Camshaft Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2858 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2859 Camshaft Position Sensor: Electrical Diagrams Camshaft Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2860 Camshaft Position Sensor: Description and Operation Camshaft Sensor PURPOSE - Sensor provides PCM with cylinder identification. - PCM uses sensor input to determine fuel injection sequence and ignition timing. OPERATION Sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). - When a notch aligns with the sensor, voltage spikes high (5.0 volts). - As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. - The number of notches determine the amount of pulses. NOTE: If available, an oscilloscope can display the square wave patterns of each timing event. NOTE: The arrows and cylinder call outs on the following image represent which cylinder the flat spot and notches identify, they do not indicate Top Dead Center (TDC) position. Camshaft Sprocket - When the PCM receives two cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder # 1 are next (on driveplate). - When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number # 2 crankshaft timing marks are next. - After 3 camshaft pulses, the PCM knows cylinder # 4 crankshaft timing marks follow. - One camshaft pulse after the three pulses indicates cylinder # 5. - The two camshaft pulses after cylinder 5 signals cylinder # 6. - The PCM can synchronize on cylinders 1 or 4. NOTE: TDC does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. NOTE: The distance between the sensor and camshaft sprocket is critical to system operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE Powertrain Management/Computers and Control Systems/Camshaft Position Sensor/Service and Repair. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2861 Camshaft Position Sensor: Service and Repair Fig. 7 Camshaft Position Sensor REMOVAL 1. Disconnect sensor electrical connector (Fig. 7). 2. Remove engine mount support bracket. 3. Loosen camshaft position sensor retaining bolt enough to allow slot in sensor to slide past the bolt. NOTE: A light tap to top of sensor prior to removal may reduce force needed for removal. 4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on the sensor case, and the O-ring may make removal difficult. INSTALLATION Notes: If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer from the sensor face completely, before attaching new spacer. If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new sensor (Fig. 5). 1. Inspect O-ring for damage, replace if necessary. 2. Ensure the O-ring is positioned in groove of the sensor, and apply a couple drops of clean engine oil to the O-ring prior to installing the sensor (Fig. 7). 3. Install sensor in the chain case cover and push sensor down until contact is made with the camshaft gear. 4. While holding the sensor in this position install and tighten the retaining bolt 14 Nm (125 in-lbs) torque. 5. Connect sensor electrical connector, and position connector away from the accessory belt 6. Install engine mount support bracket. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications NOTE: For information on how this type of sensor operates SEE, Powertrain Management/Computers and Control Systems/Coolant Temperature Sensor/Description and Operation. NOTE: Measure resistance using a high impedance Digital Volt Ohmmeter (DVOM). COLD CURVE (Reference voltage routed to sensor through PCM internal resistance of 10k ohm) Temperature ........................................................................................................................................ ........................................ Voltage -20° F ................................................................................................................................................... ....................................... 4.70 V -10° F ................................................................................................................................................... ....................................... 4.57 V 0° F ...................................................................................................................................................... ...................................... 4.45 V 10° F .................................................................................................................................................... ....................................... 4.30 V 20° F .................................................................................................................................................... ....................................... 4.10 V 30° F .................................................................................................................................................... ....................................... 3.90 V 40° F .................................................................................................................................................... ....................................... 3.60 V 50° F .................................................................................................................................................... ....................................... 3.30 V 60° F .................................................................................................................................................... ....................................... 3.00 V 70° F .................................................................................................................................................... ....................................... 2.75 V 80° F .................................................................................................................................................... ....................................... 2.44 V 90° F .................................................................................................................................................... ....................................... 2.15 V 100° F .................................................................................................................................................. ........................................ 1.83 V 110° F .................................................................................................................................................. ........................................ 1.57 V 120° F .................................................................................................................................................. ........................................ 1.25 V HOT CURVE (Reference voltage routed to sensor through PCM internal resistance of 10 k ohm) Temperature ........................................................................................................................................ ........................................ Voltage 110° F .................................................................................................................................................. ........................................ 4.20 V 120° F .................................................................................................................................................. ........................................ 4.00 V 130° F .................................................................................................................................................. ........................................ 3.77 V 140° F .................................................................................................................................................. ........................................ 3.60 V 150° F .................................................................................................................................................. ........................................ 3.40 V 160° F .................................................................................................................................................. ........................................ 3.20 V 170° F .................................................................................................................................................. ........................................ 3.02 V 180° F .................................................................................................................................................. ........................................ 2.80 V 190° F .................................................................................................................................................. ........................................ 2.60 V 200° F .................................................................................................................................................. ........................................ 2.40 V Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 2866 210° F .................................................................................................................................................. ........................................ 2.20 V 220° F .................................................................................................................................................. ........................................ 2.00 V 230° F .................................................................................................................................................. ........................................ 1.80 V 240° F .................................................................................................................................................. ........................................ 1.62 V 250° F .................................................................................................................................................. ........................................ 1.45 V Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 2867 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Crankshaft Position sensor screw .................................................................................................................................................... 12 Nm (105 in lbs) Camshaft Position sensor screw ...................................................................................................................................................... 12 Nm (105 in lbs) Coolant Sensor .......................................................................................................... .......................................................................... 7 Nm (60 in lbs) Ignition Coil .................................... ................................................................................................................................................ 12 Nm (105 in lbs) Ignition Switch ................................................................................................................... ................................................................. 2 Nm (17 in lbs) Spark Plugs ............................................. ........................................................................................................................................... 28 Nm (20 ft lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2868 Coolant Temperature Sensor/Switch (For Computer): Locations Ignition Coil And Coolant Temperature Sensor Location Sensor mounted under ignition coil. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2871 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2872 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2873 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2874 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2875 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 2876 Coolant Sensor Circuit Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2877 Coolant Temperature Sensor/Switch (For Computer): Description and Operation LOCATION The Engine Coolant Temperature (ECT) sensor is threaded into the intake manifold, next to the thermostat housing. PURPOSE The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle speed, and ignition spark advance. OPERATION The sensor element extends into the coolant passage, where it maintains constant contact with the engine coolant. The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature increases, sensor resistance decreases.) The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below. As sensor resistance changes, the voltage drop across the sensor changes. The PCM translates the voltage drop across the sensor into engine coolant temperature. THEORY As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor (cold operation), or a 909 ohm resistor (warm operation). The resistance circuits are inside the PCM. For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the 10,000 ohm resistor. When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the 909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2878 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Coolant Temperature Sensor Resistance Test 1. With key off, disconnect connector from coolant temperature sensor. 2. Connect ohmmeter across coolant temperature sensor. Resistance should read as follows; - 700 to 1,000 Ohms at approximately 200°F (operating temperature). - 7,000 to 13,000 ohms at approximately 70°F, (room temperature). 3. If resistance is not within specifications, replace sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2879 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Ignition Coil And Coolant Temperature Sensor Location REMOVAL 1. Drain cooling system until coolant level is below sensor. 2. Disconnect coil pack electrical connector to sensor. 3. Remove coil mounting screws. 4. Rotate coil away from coolant temperature sensor. 5. Disconnect electrical connector from coolant temperature sensor. 6. Remove sensor from engine. INSTALLATION 1. Tighten the coolant sensor to 7 Nm (60 in lbs) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. 4. Install coil. Tighten coil mounting screws to 12 Nm (105 in lbs) torque. 5. Connect electrical connector to coil. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2884 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position sensor screw ................................................................................................................................................ 11.9 Nm (105 in lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Crank Position Sensor The Crankshaft Position Sensor is mounted on the transaxle bellhousing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 2887 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2890 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2891 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2892 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2893 Crankshaft Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2894 Crankshaft Position Sensor Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2895 Crankshaft Position Sensor: Electrical Diagrams Crankshaft Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2896 Crankshaft Position Sensor: Description and Operation LOCATION Mounted in transmission housing, above distance sensor. PURPOSE Powertrain Control Module (PCM) uses input to determine basic timing. OPERATION Crankshaft Sensor Driveplate Sensor reads a series of slots cut in transmission driveplate. NOTE: The distance between the sensor and torque converter drive plate is critical to system operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE COMPONENT REPLACEMENT AND REPAIR PROCEDURES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2897 Crankshaft Position Sensor: Service and Repair Fig. 5 Crankshaft Position Sensor Removal 1. Disconnect sensor electrical connector (Fig. 5). 2. Remove sensor retaining bolt. 3. Pull sensor straight up, and out of the transaxle housing. Installation Notes: If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer from the sensor face completely, before attaching new spacer. If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new sensor (Fig. 5). 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. 2. While holding the sensor in this position, install and tighten the retaining bolt to 11.9 Nm (105 in-lbs) torque. 3. Connect sensor electrical connector. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Technical Service Bulletins > Diagnostic Connector - Change Data Link Connector: Technical Service Bulletins Diagnostic Connector - Change NO: 08-23-94 GROUP: Electrical DATE: May 13, 1994 SUBJECT: Diagnostic Connector Change MODELS: 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: During March, 1994 the diagnostic connector located near the steering column at the bottom of the instrument panel was changed from a blue 6-way connector to a black 8-way connector. Even though the Scan Tool (DRBII/III) has a 6-way connector, the indexing of the 8-way diagnostic connector permits the 6-way DRBII/III connector to mate with it. No special service procedures are required when mating the two connectors. The additional two pins are used during the vehicle assembly process. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Technical Service Bulletins > Page 2902 Data Link Connector: Locations Powertrain Control Module (PCM) And Data Link Connector Connector on left side of engine compartment, near battery. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Technical Service Bulletins > Page 2903 Data Link Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Data Link Connector Data Link Connector: Description and Operation Data Link Connector Powertrain Control Module (PCM) And Data Link Connector LOCATION Left side of engine compartment, near battery. Data Link Connector Identification PURPOSE Communication link to Powertrain Control Module (PCM) Technician can access inputs and memory including: - Sensor input values - Diagnostic Trouble Codes (DTC's) stored in memory - Last deactivation cause (i.e.. speed control last shut off by; speed control switch, brake switch or no crank sensor signal). Technician can actuate most PCM output devices. NOTE: Monitoring inputs, reading other memory and actuating output devices can only be accomplished through the use of a scan tool. SEE TESTING AND INSPECTION. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Data Link Connector > Page 2906 Data Link Connector: Description and Operation SCI Receive The SCI receive circuit is used as a communication path for the scan tool. The scan tool receives data through this circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Data Link Connector > Page 2907 Data Link Connector: Description and Operation SCI Transmit PURPOSE Powertrain Control Module (PCM) sends data to the scan tool through this circuit, including; - Sensor input values - Diagnostic Trouble Codes (DTC's) stored in memory - Last deactivation cause (i.e.. speed control last shut off by; speed control switch, brake switch or no crank sensor signal). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Locations Electric EGR Transducer: Locations EGR Mounting Electric EGR Transducer (EET) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Locations > Page 2911 EGR System Mounted near the throttle body. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Description and Operation > Backpressure Transducer Operation Electric EGR Transducer: Description and Operation Backpressure Transducer Operation EGR Mounting Electric EGR Transducer (EET) NOTE: The Electric EGR Transducer (EET) assembly is a vacuum control solenoid and a backpressure transducer, in one package. PURPOSE When the solenoid is de-energized the transducer varies the amount of vacuum routed to the EGR valve control nipple, (depending on engine load conditions). OPERATION Transducer is supplied ported vacuum through the solenoid. Transducer is a variable vacuum bleed valve, controlled by exhaust backpressure. When there is no exhaust backpressure, the vacuum bleed valve is completely open, and no vacuum is applied to the EGR valve. - When exhaust backpressure is great enough, it closes the vacuum bleed valve completely, and maximum vacuum is applied to the EGR valve. - When exhaust backpressure is present, but not great enough to close the vacuum bleed valve completely, the vacuum applied to the EGR valve varies with the backpressure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Description and Operation > Backpressure Transducer Operation > Page 2914 Electric EGR Transducer: Description and Operation Electric EGR Transducer (EET) Vacuum Control Solenoid Valve Operation EGR Mounting Electric EGR Transducer (EET) NOTE: The EET assembly is a vacuum control solenoid and a backpressure transducer, in one package. PURPOSE The PCM controls when the EGR valve can be actuated, through the solenoid valve portion of the Electronic EGR Transducer (EET). OPERATION Ported vacuum from the throttle body, is supplied to the solenoid valve. The PCM controls the flow of vacuum between the throttle body and the back pressure transducer, (through the solenoid ground circuit). - When the solenoid is energized (grounded), no vacuum is supplied to the transducer. - When the solenoid is de-energized (not grounded), vacuum is supplied to the transducer. The solenoid will always be energized (no EGR), under following conditions: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Description and Operation > Backpressure Transducer Operation > Page 2915 - Engine warm-up, (engine coolant temperature below 40 ~F) - Engine at idle - Wide Open Throttle (WOT) operation - Rapid acceleration/deceleration - During EGR system diagnostic check NOTE: If the wiring or connector is disconnected from the solenoid, the EGR valve will operate at all times, (adversely affecting engine idle and performance). Backpressure Transducer Operation EGR Mounting Electric EGR Transducer (EET) NOTE: The Electric EGR Transducer (EET) assembly is a vacuum control solenoid and a backpressure transducer, in one package. PURPOSE When the solenoid is de-energized the transducer varies the amount of vacuum routed to the EGR valve control nipple, (depending on engine load conditions). OPERATION Transducer is supplied ported vacuum through the solenoid. Transducer is a variable vacuum bleed valve, controlled by exhaust backpressure. When there is no exhaust backpressure, the vacuum bleed valve is completely open, and no vacuum is applied to the EGR valve. - When exhaust backpressure is great enough, it closes the vacuum bleed valve completely, and maximum vacuum is applied to the EGR valve. - When exhaust backpressure is present, but not great enough to close the vacuum bleed valve completely, the vacuum applied to the EGR valve Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Description and Operation > Backpressure Transducer Operation > Page 2916 varies with the backpressure. Diagnostic Check Operation The solenoid disables the EGR system periodically, to allow the PCM to perform a diagnostic check. - During a diagnostic check, (activated only during select engine/driving conditions), the PCM tests the entire EGR system for failures. - If the PCM detects an EGR system failure, the Malfunction Indicator Lamp (MIL), (previously called the Check Engine Lamp), in the instrument panel will be illuminated, indicating that immediate service is required. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electric EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Description and Operation > Page 2917 Electric EGR Transducer: Service and Repair EGR Mounting REMOVAL 1. Disconnect EGR transducer electrical connector and vacuum hose. (Inspect vacuum hose for any damage.) 2. Remove EGR valve to intake manifold bolts. 3. Open transducer clip and remove transducer. 4. Remove EGR valve. 5. Clean gasket surface and discard old gasket. 6. Inspect for signs of leakage or cracks. INSTALLATION 1. Loosely install EGR valve with new gasket. 2. Torque bolts to 200 in lb (22 Nm). 3. Install transducer in clip with orientation tab in slot and snap closed. 4. Connect vacuum hose and electrical connector. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > High Altitude Kit - Installation Powertrain Control Module: Technical Service Bulletins High Altitude Kit - Installation NO.: 25-01-93 GROUP: Emissions DATE: Sep. 3, 1993 SUBJECT: High Altitude Kits MODELS: 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country SYMPTOM/CONDITION: The 1994 AS Body Owners Manual makes reference to the availability of high altitude kits (1st page of the Starting and Operating section) that can be used if the owner changes his residence from an area of low altitude to one of high altitude. These kits are required by the EPA for some 1994 federally certified AS body vehicles to comply with high altitude emissions standards. The high altitude kit will have no effect on vehicle performance or driveability. DIAGNOSIS: Vehicles for which these kits are available have the following statement on the Vehicle Emission Control Information (VECI) label: "CONVERSION KIT REQUIRED FOR HIGH ALTITUDE - SEE OWNERS MANUAL". The high altitude kit must be installed if requested by the vehicle owner, at the owner's expense. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the PCM, VECI label and installing an Authorized Modification label. 1. Using the procedure outlined on either page 14-51 or 14-112 of the 1994 Front Wheel Drive/All Wheel Drive Van/Wagon Service Manual, replace the PCM with the appropriate PCM specified in the "Parts Required" section of this bulletin. 2. Use Mopar Tar Remover (P/N 4549601) to clean the surface of the VECI label and the area of the dash panel that the new labels will be attached to. 3. Attach the new VECI label on top of the original label. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > High Altitude Kit - Installation > Page 2922 4. Type in the required information on the Authorized Modification label (P/N 4275086) as illustrated, and attach next to the VECI label. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations Powertrain Control Module (PCM) And Data Link Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 2925 Powertrain Control Module (PCM) And Data Link Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2928 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2929 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2930 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2931 Powertrain Control Module: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2932 Powertrain Control Module 60 Way Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Idle Air Control Motor - Whistling Noise Idle Speed/Throttle Actuator - Electronic: Technical Service Bulletins Idle Air Control Motor Whistling Noise NO.: 14-09-93 Rev.A GROUP: Fuel DATE: Nov. 12, 1993 SUBJECT: Idle Air Control Motor Whistle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NO. 14-09-93 DATED 6-4-93, WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. CHANGES INCLUDE MODELS & DIAGNOSIS REVISION. MODELS: ** 1991 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon (AY) Imperial/New Yorker Fifth Avenue 1991 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country** 1993 (LH) Concorde/Intrepid/Vision 1994 (LH) LHS/New Yorker **NOTE: THIS BULLETIN APPLIES TO 3.3L & 3.8L AC & AY; 3.3L AS BUILT PRIOR TO MDH 1108XX; AND LH MODELS BUILT PRIOR TO MDH 0726XX.** SYMPTOM/CONDITION: Vehicle exhibits a high-pitched whistling noise from the engine compartment at idle. The noise may be more prevalent when the engine is under a load such as air conditioning or headlamps on. No whistling can be heard while cruising. DIAGNOSIS: **Place the gear selector in park, set the parking brake, and start the engine. Let the engine idle for several minutes (3 to 5 minutes). Verify there are no vacuum leaks in the engine compartment. Increase the engine RPM's to around 1200 using the throttle. If the whistle sound goes away, perform the repair procedure below. If the whistle does not go away see Technical Service Bulletin No. 21-01-93 published 1-13-93.** PARTS REQUIRED: 1 4612673 Idle Air Control Motor REPAIR PROCEDURE: This bulletin involves the replacement of the idle air control motor. 1. Using the procedures outlined in the appropriate Service Manual, replace the idle air control motor. 2. Run the engine at idle to verify the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 14-30-23-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations Idle Speed/Throttle Actuator - Electronic: Component Locations Throttle Body View With Idle Air Control Motor Idle Air Control Motor And Throttle Position Sensor Mounted on throttle body. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations > Page 2939 Idle Speed/Throttle Actuator - Electronic: Connector Locations Throttle Body View With Idle Air Control Motor - Mounted on throttle body. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 2942 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 2943 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 2944 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 2945 Idle Speed/Throttle Actuator - Electronic: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 2946 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 2947 Idle Air Control Motor Circuit Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 2948 Idle Speed/Throttle Actuator - Electronic: Description and Operation Throttle Body View With Idle Air Control Motor LOCATION Mounted on throttle body. PURPOSE Maintains optimum idle speed under varying engine loads. Prevents deceleration die out. OPERATION Powertrain Control Module (PCM) calculates proper idle speed using information from throttle position, vehicle speed, and coolant temperature sensors and brake, and neutral/safety switches. PCM controls idle speed by actuating motor, varying air flow through bypass in throttle body. Prevents decel die out by increasing air flow when throttle is closed suddenly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 2949 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection NOTE: Idle Air Control (IAC) motor operation can be tested using a scan tool. CAUTION: Proper safety precautions must be taken when testing the IAC motor. - Set the parking brake and block the drive wheels - Route all scan tool cables away from the cooling fans, drive belt, pulleys. and exhaust components - Provide proper ventilation while operating the engine - Always return the engine idle speed to normal before disconnecting the exerciser tool. - Follow scan tool manufacturer's instructions for testing the IAC motor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 2950 Idle Speed/Throttle Actuator - Electronic: Service and Repair Throttle Body View With Idle Air Control Motor Removal 1. Disconnect the negative battery cable. 2. Disconnect motor wiring connector. 3. Remove motor mounting screws (2-25 mm long, Torx head screws), and remove motor, (make sure the O-ring is removed from throttle body). Idle Air Control (IAC) Motor Installation Installation NOTE: If the pintle measures more than 1 in (25 mm), it must be retracted using scan tool [1]. 1. Install motor using a new O-ring, and torque mounting screws to 20 in-lbs (2 Nm). 2. Connect motor wiring connector. 3. Install air cleaner assembly. 4. Connect negative battery cable. Remarks Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 2951 [1] Follow scan tool manufacturer's instructions. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations > CCD Data Link Connector Location Information Bus: Locations CCD Data Link Connector Location Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations > CCD Data Link Connector Location > Page 2956 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Service Precautions > Technician Safety Information Information Bus: Technician Safety Information - When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as watchbands or bracelets that might make inadvertent electrical contact. - When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests. - Some components of the body system are intended to be serviced in assembly only. Attempting to remove or repair certain system sub-components may result in personal injury and/or improper system operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Service Precautions > Technician Safety Information > Page 2959 Information Bus: Vehicle Damage Warnings - Make sure the ignition is OFF before disconnecting any control module. Failure to do so could damage the module. - When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail due to corrosion. - Be careful when performing electrical tests to prevent accidental shorting of terminals. Such mistakes can damage fuses or components and will sometimes set a second code, making diagnosis of the original problem more difficult. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Application and ID > Glossary of Terms Information Bus: Application and ID Glossary of Terms ACM - Air Bag Control Module ATC - Automatic Temperature Control BCM - Body Control Module CAB - Controller-Antilock Brake CCD - Chrysler Collision Detection (vehicle communications bus) EIC - Electronic Instrument Cluster MIC - Mechanical Instrument Cluster PCM - Powertrain Control Module TCM - Transmission Control Module VTSS - Vehicle Theft Security System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Application and ID > Glossary of Terms > Page 2962 Information Bus: Application and ID Vehicle Body Code ID CARS AA Chrysler LeBaron (4-door), Dodge Spirit, Plymouth Acclaim AC Chrysler New Yorker Salon, Dodge Dynasty AG Dodge Daytona AJ Chrysler LeBaron (2-door) AP Dodge Shadow, Plymouth Sundance AS Chrysler Town and Country, Dodge Caravan and Grand Caravan, Plymouth Voyager and Grand Voyager AY Chrysler Imperial, Chrysler Fifth Avenue FJ22 Chrysler Sebring Dodge Avenger FJ24 Eagle Talon JA Chrysler Cirrus Plymouth Cirrus Dodge Stratus LH Chrysler Concorde Chrysler, LHS, Chrysler New Yorker, Dodge Intrepid, Eagle Vision PL Dodge Neon, Plymouth Neon SR Dodge Viper TRUCKS AB Dodge Ram (Van / Wagon) 150, 250, 350 AD Dodge Ram (Pickup) 150, 250, 350 Dodge Ramcharger AN Dodge Dakota BR Dodge Ram (Pickup) 1500, 2500, 3500 BT Dodge Ram (Cab) 1500, 2500, 3500 ES Chrysler Grand Voyager, Chrysler Ram Van MJ Jeep Comanche XJ Jeep Cherokee YJ Jeep Wrangler ZJ Jeep Grand Cherokee Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > CCD Bus Information Bus: Description and Operation CCD Bus PURPOSE: The CCD bus relays information about the operation of vehicle components and circuits to the appropriate module(s). OPERATION The body system consists of a combination of modules that communicate over the Chrysler Collision Detection multiplex system (CCD bus). Each module receives the same information about a component or circuit as the other modules do. This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. The CCD Bus may be used for communication between the Vehicle Theft Alarm (VTA) module, instrument panel, scan tool, and the Powertrain Control Module (PCM). The CCD Bus is both an input and output from the Vehicle Theft Alarm (VTA) module. Circuit D1 is used for CCD (+) and circuit D2 is used for CCD (-). These circuits are connected in with the data link connector and the Powertrain Control Module (PCM). Bus Information is Coded The CCD bus receives and delivers coded information between the modules. The information is coded to identify the message as well as the importance of the message. - When there are multiple messages trying to access the CCD bus at one time, the message with higher priority is allowed to access the bus first. Twisted Pair CCD bus consists of a twisted pair of wires that run from one module to another. The two wires (D1) and (D2) of the twisted pair that make up the CCD multiplex system are called "bus +", (bus plus) and "bus -", (bus minus) respectively. - Each wire has a measurable voltage level of roughly 2.5 volts. Voltage Divider Network Bias and Termination In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network." This network consists of some modules with bias and some with termination. Bias is the part of the voltage divider network that places both bus+ and bus- at 2.5 volts. - Termination in the circuitry is required to complete the voltage divider network and also to provide some electromagnetic protection for the bus. NOTE: Modules using the CCD bus can be identified by accessing them through the CCD bus using a scan tool with the correct connector and cartridge. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > CCD Bus > Page 2965 Information Bus: Description and Operation Modules Connected to Body Control Module Some of the instructions tell you to disconnect a module that may not be available on this vehicle. Above is a matrix of modules and bodies showing the modules each vehicle is equipped with. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics Information Bus: Component Tests and General Diagnostics NOTE: Use these procedures only when instructed to do so by another test procedure. TIP: Verify that the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. CAUTION: Be careful when performing electrical tests to prevent accidental shorting of terminals. Such mistakes can damage fuses or components and will sometimes set a second code, making diagnosis of the original problem more difficult. To efficiently diagnose CCD bus problems follow these six steps: 1. Verify Complaint 2. Check for Related Symptoms 3. Analyze Symptoms 4. Isolate the Problem 5. Repair the Isolated Problem 6. Verify Proper Operation ROAD TESTING Some complaints will require a test drive to duplicate the diagnostic code or symptom condition and to verify the repair. CAUTIONS: Before road testing a vehicle, be sure that all components are reassembled. - During the test drive, do not try to read the scan tool screen while in motion. - Do not hang the scan tool from the rear view mirror or operate it yourself. Have an assistant available to operate the scan tool. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Page 2968 Information Bus: Tools and Equipment The following tools are recommended to properly diagnose CCD bus problems: - Scan tool -- with correct cartridge and connector - Jumper Wires - Ohmmeter - Oil Pressure Gauge - Voltmeter Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Auto Sutdown Relay In the Power Distribution Center left side of engine compartment. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2972 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2973 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2976 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2977 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2978 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2979 Automatic Shut Down (ASD) Relay: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2980 Automatic Shut Down (ASD) Relay: Description and Operation Relay Locations PURPOSE Relay supplies battery voltage to the ignition coil and fuel injector(s). OPERATION Ignition switch in the START or RUN position, and PCM is receiving reference signals from the distributor pick-up. The Powertrain Control Module (PCM) activates the relay (by supplying a ground). If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM interrupts the relay ground and no voltage is supplied to the ignition coil, or fuel injector(s). NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through the same ground circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay NOTE: Relay terminal numbers can be found on the bottom of the relay: TERMINAL IDENTIFICATION - Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times. - Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the components being operated. - Terminal number 86 is connected to a switched (B+) power source (ignition in ON or RUN). - Terminal number 85 is grounded by the PCM. PROCEDURE 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value (ohms) should be 75 ± 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 Volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. Continuity should now be present between terminals number 87 and 30. Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 Volt power source. - If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring Diagrams for fuel system wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Locations Malfunction Indicator Lamp: Locations NOTE: MIL previously called Check Engine Lamp (CEL). Light in instrument panel. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Locations > Page 2986 Malfunction Indicator Lamp: Description and Operation NOTE: Malfunction Indicator Lamp (MIL), previously called Check Engine Lamp (CEL). PURPOSE Indicates immediate service of engine control system is required. Informs driver that he has entered "Limp-In" mode, lamp ON while vehicle is being driven. Displays Diagnostic Trouble Codes (DTC's), stored in memory. OPERATION Illuminates for three seconds when ignition switch is turned ON, (for bulb test). Illuminates if Powertrain Control Module (PCM) receives an out of range input from a monitored circuit, or, (for vehicles with California emissions), from an emission related device. - Signals that can set Malfunction Indicator Lamp are battery voltage input, charging system, Manifold Absolute Pressure (MAP), sensor, Throttle Position Sensor (TPS), Engine Coolant Temperature (ECT) sensor. Can be used to display any DTC's stored in memory, SEE POWERTRAIN MANAGEMENT/COMPUTERS AND CONTROL SYSTEMS/TESTING AND INSPECTION. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications Vacuum in Inches of Mercury MAP sensor Signal Voltage .39 in Hg .............................................................................................................................................. .............................. 4.90 V 3.34 in Hg ............................................................................................................................................ ............................... 4.60 V 6.30 in Hg ............................................................................................................................................ ............................... 3.60 V 9.25 in Hg ............................................................................................................................................ ............................... 3.10 V 12.20 in Hg .......................................................................................................................................... ................................ 2.60 V 15.15 in Hg .......................................................................................................................................... ................................ 2.10 V 18.11 in Hg .......................................................................................................................................... ................................ 1.60 V 21.06 in Hg .......................................................................................................................................... ................................ 1.10 V 24.01 in Hg .......................................................................................................................................... ................................ 0.60 V 26.97 in Hg .......................................................................................................................................... ................................ 0.31 V Condition ............................................................................................................................................. .................................. Expected Output Voltage High Vacuum (Idle/Deceleration) ............................................................................................................................................................. 0.5 to 1.5 volts Medium Vacuum (Cruise/Slight Acceleration) ......................................................................................................................................... 1.5 to 3.0 volts Low Vacuum (Hard Acceleration/Mechanical Failure) ............................................................................................................................. 3.0 to 4.5 volts NOTE: Any reading of 0 volts or over 5 volts indicates a problem in the MAP sensor circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations Manifold Pressure/Vacuum Sensor: Component Locations Engine Control Component Locations Back Side Of Intake Plenum View Sensor mounted on back side of intake plenum. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations > Page 2992 Back Side Of Intake Plenum View Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions Manifold Pressure/Vacuum Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2995 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2996 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2997 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2998 Manifold Pressure/Vacuum Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2999 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3000 MAP Sensor Circuit Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 3001 Manifold Pressure/Vacuum Sensor: Description and Operation LOCATION Sensor mounted on intake plenum. PURPOSE At start-up, the Powertrain Control Module (PCM) uses sensor to read barometric (atmospheric), pressure, for reference, to calculate air/fuel mixture. During operation the Powertrain Control Module (PCM) monitors sensor input to adjust spark advance and air/fuel mixture. OPERATION PCM supplies 5 volt sensor reference voltage. Sensor, connected to manifold vacuum at throttle body, converts intake manifold pressure into voltage. THEORY Sensor resistance and manifold absolute pressure are inversely proportional (as manifold absolute pressure increases, (low vacuum), sensor resistance decreases and vice versa). OUTPUT VOLTAGES Sensor output voltage range is 0.5 to 4.5 volts. - Output voltages between 0.5 and 1.5 volts indicate a high vacuum situation, such as idle or deceleration. - Output voltages between 1.5 and 3.0 volts indicate a medium level of vacuum such as a cruise or slight acceleration condition. - Output voltages between 3.0 and 4.5 volts indicate a low vacuum situation such as hard acceleration or a mechanical failure. - Any reading of 0 volts or over 5 volts indicates a problem. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 3002 Manifold Pressure/Vacuum Sensor: Testing and Inspection NOTE: To perform a complete test of the Manifold Absolute Pressure (MAP) sensor and its circuitry, refer to appropriate Diagnostic Chart. See: Testing and Inspection TO TEST THE MAP SENSOR ONLY: 1. Inspect the rubber nipple (fitting) from the MAP sensor to the throttle body. Repair as necessary. CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 2. Test the MAP sensor output voltage at the MAP sensor connector terminal 2. With the ignition switch ON, and the engine OFF. Output voltage should be 4 to 5 volts. 3. Test the MAP sensor output voltage at the MAP sensor connector terminal 2 at a hot, neutral idle speed condition. The voltage should drop to 1.5 to 2.1 volts. 4. Test PCM (terminal / pin-5) for the same voltage described above to verify the wire harness condition. Repair as necessary. 5. Test MAP sensor supply voltage at sensor connector terminal 3 with the ignition ON. The voltage should be approximately 5 volts (±O.5 V). 5 volts (±0.5 Volts). should also be present at terminal 6 of the PCM wire harness connector. Repair or replace the wire harness as necessary. 6. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM connector terminal / pin-4. Repair the wire harness if necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 3003 Manifold Pressure/Vacuum Sensor: Service and Repair MAP" Sensor Removal 1. Disconnect vacuum hose and electrical connector from sensor. 2. Remove sensor mounting screws and remove sensor. Installation 1. Install sensor and tighten screws. 2. Connect vacuum hose and electrical connector from sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Air/Fuel Oxygen Exhaust Ratio Sensor Voltage Gas Content 12.0:1 1.0 Volts [1] 5.0% CO [2] 13.0:1 0.85 Volts 3.8% CO [2] 14.0:1 0.65 Volts 1.3% CO [2] 14.7:1 0.45 Volts [5] 0.1% CO [2] 15.0:1 0.35 Volts 2.0% O2 [3] 16.0:1 0.25 Volts 3.0% O2 [3] 17.0:1 0.10 Volts [4] 4.0% O2 [3] Remarks [1] Full rich condition. [2] CO: Carbon monoxide, is a sign of incomplete ignition, (not enough oxygen to burn all the hydrocarbons in cylinder). [3] O2: Oxygen left over after all hydrocarbons have been burned. [4] Full lean condition. [5] Stoichiometric point: Output voltages below 0.45 volts indicate a lean condition, and output voltages over 0.45 volts indicate a rich condition. NOTE: Both lean and rich conditions are usually accompanied by high Hydrocarbon (HC) readings. Due to not enough fuel, (lean misses), or too much fuel, (not enough oxygen to burn all hydrocarbons). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations EGR Mounting Sensor threaded into exhaust manifold, just above flange. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3009 Back Side Of Intake Plenum View Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3012 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3013 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3014 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3015 Oxygen Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3016 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3017 Oxygen Sensor: Electrical Diagrams Oxygen Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3018 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3019 Oxygen Sensor: Description and Operation O2 Sensor Cutaway View (Typical) SENSOR PURPOSE Powertrain Control Module (PCM) uses input to determine whether to enrich or lean air/fuel mixture, during closed loop operation. SENSOR OPERATION The oxygen sensor generates a varying voltage signal dependent upon exhaust gas oxygen content at that point in the exhaust. - Oxygen sensor voltage signal is produced through a galvanic reaction within the sensors. Using the oxygen sensor voltage signal as an air/fuel ratio indicator the PCM can tell how well the system is responding to its output signals. - Changes in the sensor signal occur because the air/fuel ratio is constantly changing. - When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. - When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. Closed Loop During CLOSED LOOP operation, the PCM monitors the signals it receives from the oxygen sensor, and other sensors, and uses these signals to adjust the injector pulse width according to the current driving condition. Open Loop During OPEN LOOP operation, the PCM ignores the oxygen sensor's signals, and other sensor's signals, and adjusts injector pulse widths according to preprogrammed specifications in the PCM. HEATER PURPOSE Vehicle enters CLOSED LOOP faster, (because sensor reaches operating temperature sooner). Allows CLOSED LOOP operation during extended idle, (because heater maintains correct operating temperature). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test Oxygen Sensor: Testing and Inspection Powertrain Control Module Response Test Oxygen Sensor And Connector NOTE: This test should be performed only after the Oxygen Sensor (O2S) has passed the functional test and heating element test. NOTE: A four gas analyzer is needed to perform this test. NOTE: When performing this test it is important that no part of your body contact the vehicle body, as test results will be inaccurate. CAUTION: NEVER apply voltage directly to any computer sensor wire. PRECONDITIONING AND SET UP 1. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T), (to ensure vehicle and oxygen sensor are at operating temperature and vehicle is in closed loop). 2. Turn engine OFF, disconnect the oxygen sensor connector. Connect a jumper lead to the O2S signal wire. 3. Start the engine and run at 2,500 rpm for 1 minute, with the transmission in PARK (A/T), or NEUTRAL (M/T). 4. Let idle. LEAN MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO ENRICH MIXTURE) 1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery negative, hold for 10 to 20 seconds. - The CO and HC readings should increase, as the PCM opens the injectors for longer periods (longer pulse width), to enrich the mixture. 2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or engine control system will be necessary. SEE DIAGNOSIS BY SYMPTOM. RICH MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO LEAN OUT MIXTURE) 1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery positive, hold for 10 to 20 seconds. - The O2 readings should begin to increase, and the CO reading should decrease. 2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or engine control system will be necessary. SEE DIAGNOSIS BY SYMPTOM. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test > Page 3022 Oxygen Sensor: Testing and Inspection Sensor Functional Test Oxygen Sensor And Connector CAUTION: Use a high impedance [1] Digital Volt Ohm Meter (DVOM) ONLY, when testing components on computerized vehicles. 1. Make sure the vehicle is at normal operating temperature. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T). CAUTION: To avoid damaging sensor, voltmeter must be set in Volts mode only, (not ohms). 2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to read DC VOLTS. Disconnect the oxygen sensor ( O2S) electrical connector and connect the positive lead of the DVOM to the oxygen sensor signal wire. 3. Start engine. Create a lean condition for 10 seconds. Voltage should decrease to 0.2 volt or less and remain there. 4. Create a rich condition for 10 seconds. Voltage should increase to 0.8 volt or more and remain there. 5. If sensor fails to vary according to the test steps above, the sensor is defective. 6. Connect sensor and clear codes. Remarks: [1] Minimum 10 Meg (10,000,000) ohm input impedance. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test > Page 3023 Oxygen Sensor: Testing and Inspection Sensor Heating Element Test Oxygen Sensor And Connector Oxygen Sensor Connector Identification And PINOUT 1. Disconnect the Heated Oxygen Sensor (O2S), electrical connector from the wiring harness. 2. Set DVOM to read OHMS. Connect the ohmmeter between the heater feed and heater ground (terminals 3 and 4), of the sensor electrical connector. 3. Resistance should be between 5 and 7 ohms, if not replace the sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Page 3024 Oxygen Sensor: Service and Repair Oxygen Sensor Location (Typical) Oxygen Sensor Socket WARNING: Avoid physical contact with hot exhaust components. CAUTION: Do not pull on or cut sensor wires, when removing sensor. CAUTION: Use of excessive force may damage threads in exhaust manifold or pipe. REMOVAL 1. Disconnect oxygen sensor electrical connector. 2. Using a suitable tool (Snap-On socket YA8875, or equivalent), carefully remove the sensor from exhaust manifold or pipe. (Slightly tightening the sensor before removal may ease removal.) 3. Clean threads in exhaust manifold with an 18 mm X 1.5 + 6E tap. INSTALLATION 1. If a new sensor is being used, verify that the threads are coated with anti-seize compound, before installing in manifold or pipe. 2. If sensor is being reused, coat sensor threads with a nickel based anti-seize compound, (Loctite 771-64 or equivalent). CAUTION: Do not use graphite or other anti-seize compounds. 3. Install sensor, and tighten to 27 Nm (20 ft-lbs). 4. Connect wiring. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly Body Controller: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 3034 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly Body Controller: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly > Page 3040 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > Page 3041 Body Control Module System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Body Controller: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3044 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3045 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3046 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3047 Body Controller: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3048 Body Controller: Connector Views Body Control Module Blue Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3049 Body Control Module Natural Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3050 BCM Natural Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3051 BCM Blue Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and ID > BCM Identification Body Controller: Application and ID BCM Identification There are two different body control modules available on these vehicles; One supports the mechanical instrument cluster as well as the electro/mechanical instrument cluster. - The other supports the electronic instrument cluster. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and ID > BCM Identification > Page 3054 Body Controller: Application and ID Glossary of Terms BCM - Body Control Module CCD - Chrysler Collision Detection (Vehicle Communications Bus) CMTC - Compass/mini-trip Computer (module) DLC - Data Link Connector (previously Called "Diagnostic Connector") DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument Cluster ET - Elapsed Time IOD - Ignition Off Draw MET - Metric MIC - Mechanical Instrument Cluster ODO - Odometer PCM - Powertrain Control Module PDC - Power Distribution Center RKE Remote Keyless Entry Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and ID > Page 3055 Body Controller: Description and Operation PURPOSE The body control module: Provides power or ground for a variety of systems and uses a voltage drop to monitor these systems. - Is the only module that has the capability of providing both bias and termination on the CCD bus system. - Is used to store odometer information displayed in the electronic instrument cluster. OPERATION The body systems are monitored by individual control modules, which send information about their operation to the body control module over the CCD (Chrysler Collision Detection multiplex system) bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed to the appropriate module(s). - Each module receives the same information about a component or circuit as another module does. - This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. BODY SYSTEM COVERAGE: - Automatic Door Locks - Compass/mini-trip Module - Courtesy Lamps - Electronic Instrument Cluster (EIC) - Electro/mechanical Instrument Cluster - Mechanical Instrument Cluster (MIC) - Illuminated Entry - Remote Keyless Entry (RKE) - Intermittent Wipers - Liftgate Release NOTE: Communication over the CCD bus is essential to the proper operation of vehicle on-board diagnostic systems and scan tool communication. Bus or scan tool problems must be corrected before proceeding with diagnostic testing. If there is a problem, refer to Vehicle Communications (CCD) Bus/Testing and Inspection for diagnosis and repair procedures. TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is not set or if it is set incorrectly, any speed-related accessories will not operate or will operate inaccurately. - This includes the speedometer, speed control, rolling door locks, and other devices that are operated by the powertrain and body controllers. - For instructions on setting the pinion factor, see the appropriate transmission section. GLOSSARY OF TERMS BCM - Body Control Module CCD - Chrysler Collision Detection (vehicle Communications Bus) CMTC - Compass/mini-trip Computer (module) DLC - Data Link Connector (previously Called "diagnostic Connector") DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument Cluster ET - Elapsed Time IOD - Ignition Off Draw MET - Metric MIC - Mechanical Instrument Cluster ODO - Odometer PCM - Powertrain Control Module PDC - Power Distribution Center RKE Remote Keyless Entry Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Controller: Component Tests and General Diagnostics Diagnostic Notes - Read First TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is not set or if it is set incorrectly, any speed-related accessories will not operate or will operate inaccurately. - This includes the speedometer, speed control, rolling door locks, and other devices that are operated by the powertrain and body controllers. - For instructions on setting the pinion factor, see the appropriate transmission section. NOTE: These diagnostics are based on the failure condition or symptom being present at the time of diagnosis. TIPS: Verify that the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Be careful when performing electrical tests to prevent accidental shorting of terminals. Such mistakes can damage fuses or components and will sometimes set a second code, making diagnosis of the original problem more difficult. WARNINGS: - When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as watchbands or bracelets that might make an inadvertent electrical contact. - When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests. To efficiently diagnose CCD bus problems follow these six steps: 1. Verify Complaint 2. Check for Related Symptoms 3. Analyze Symptoms 4. Isolate the Problem 5. Repair the Isolated Problem 6. Verify Proper Operation ROAD TESTING Some complaints will require a test drive to duplicate the diagnostic code or symptom condition and to verify the repair. CAUTIONS: Before road testing a vehicle, be sure that all components are reassembled. - During the test drive, do not try to read the scan tool screen while in motion. - Do not hang the scan tool from the rear view mirror or operate it yourself. Have an assistant available to operate the scan tool. TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is not set or if it is set incorrectly, any speed-related accessories will not operate or will operate inaccurately. - This includes the speedometer, speed control, rolling door locks, and other devices that are operated by the powertrain and body controllers. - For instructions on setting the pinion factor, see the appropriate transmission section. Description of On-Board Diagnostics A scan tool is required to read body system trouble codes. However, not all body system problems have a corresponding trouble code. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 3058 Body Controller: Scan Tool Testing and Procedures If the scan tool Does Not Power Up; Check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). If all connections are proper between scan tool and the vehicle, and the vehicle battery is fully charged, an inoperative scan tool may be the result or faulty cable or vehicle wiring. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and Inspection > Page 3059 Body Controller: Tools and Equipment The following tools are recommended to properly diagnose CCD bus problems: - Scan tool -- with correct cartridge and applicable connectors. - Jumper Wires - Ohmmeter - Oil Pressure Gauge - Voltmeter Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > High Altitude Kit - Installation Powertrain Control Module: Technical Service Bulletins High Altitude Kit - Installation NO.: 25-01-93 GROUP: Emissions DATE: Sep. 3, 1993 SUBJECT: High Altitude Kits MODELS: 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country SYMPTOM/CONDITION: The 1994 AS Body Owners Manual makes reference to the availability of high altitude kits (1st page of the Starting and Operating section) that can be used if the owner changes his residence from an area of low altitude to one of high altitude. These kits are required by the EPA for some 1994 federally certified AS body vehicles to comply with high altitude emissions standards. The high altitude kit will have no effect on vehicle performance or driveability. DIAGNOSIS: Vehicles for which these kits are available have the following statement on the Vehicle Emission Control Information (VECI) label: "CONVERSION KIT REQUIRED FOR HIGH ALTITUDE - SEE OWNERS MANUAL". The high altitude kit must be installed if requested by the vehicle owner, at the owner's expense. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the PCM, VECI label and installing an Authorized Modification label. 1. Using the procedure outlined on either page 14-51 or 14-112 of the 1994 Front Wheel Drive/All Wheel Drive Van/Wagon Service Manual, replace the PCM with the appropriate PCM specified in the "Parts Required" section of this bulletin. 2. Use Mopar Tar Remover (P/N 4549601) to clean the surface of the VECI label and the area of the dash panel that the new labels will be attached to. 3. Attach the new VECI label on top of the original label. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > High Altitude Kit - Installation > Page 3064 4. Type in the required information on the Authorized Modification label (P/N 4275086) as illustrated, and attach next to the VECI label. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations Powertrain Control Module (PCM) And Data Link Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 3067 Powertrain Control Module (PCM) And Data Link Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3070 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3071 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3072 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3073 Powertrain Control Module: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3074 Powertrain Control Module 60 Way Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Auto Sutdown Relay In the Power Distribution Center left side of engine compartment. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3078 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3079 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3082 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3083 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3084 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3085 Automatic Shut Down (ASD) Relay: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3086 Automatic Shut Down (ASD) Relay: Description and Operation Relay Locations PURPOSE Relay supplies battery voltage to the ignition coil and fuel injector(s). OPERATION Ignition switch in the START or RUN position, and PCM is receiving reference signals from the distributor pick-up. The Powertrain Control Module (PCM) activates the relay (by supplying a ground). If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM interrupts the relay ground and no voltage is supplied to the ignition coil, or fuel injector(s). NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through the same ground circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay NOTE: Relay terminal numbers can be found on the bottom of the relay: TERMINAL IDENTIFICATION - Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times. - Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the components being operated. - Terminal number 86 is connected to a switched (B+) power source (ignition in ON or RUN). - Terminal number 85 is grounded by the PCM. PROCEDURE 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value (ohms) should be 75 ± 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 Volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. Continuity should now be present between terminals number 87 and 30. Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 Volt power source. - If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring Diagrams for fuel system wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3094 Camshaft Position Sensor: Mechanical Specifications Camshaft Position sensor screw ..................................................................................................................................................... 14 Nm (125 in lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor Location The Camshaft Position (CMP) sensor is located on the timing gear cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 3097 Camshaft Position Sensor Location Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3100 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3101 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3102 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3103 Camshaft Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3104 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3105 Camshaft Position Sensor: Electrical Diagrams Camshaft Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3106 Camshaft Position Sensor: Description and Operation Camshaft Sensor PURPOSE - Sensor provides PCM with cylinder identification. - PCM uses sensor input to determine fuel injection sequence and ignition timing. OPERATION Sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). - When a notch aligns with the sensor, voltage spikes high (5.0 volts). - As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. - The number of notches determine the amount of pulses. NOTE: If available, an oscilloscope can display the square wave patterns of each timing event. NOTE: The arrows and cylinder call outs on the following image represent which cylinder the flat spot and notches identify, they do not indicate Top Dead Center (TDC) position. Camshaft Sprocket - When the PCM receives two cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder # 1 are next (on driveplate). - When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number # 2 crankshaft timing marks are next. - After 3 camshaft pulses, the PCM knows cylinder # 4 crankshaft timing marks follow. - One camshaft pulse after the three pulses indicates cylinder # 5. - The two camshaft pulses after cylinder 5 signals cylinder # 6. - The PCM can synchronize on cylinders 1 or 4. NOTE: TDC does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. NOTE: The distance between the sensor and camshaft sprocket is critical to system operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE Powertrain Management/Computers and Control Systems/Camshaft Position Sensor/Service and Repair. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3107 Camshaft Position Sensor: Service and Repair Fig. 7 Camshaft Position Sensor REMOVAL 1. Disconnect sensor electrical connector (Fig. 7). 2. Remove engine mount support bracket. 3. Loosen camshaft position sensor retaining bolt enough to allow slot in sensor to slide past the bolt. NOTE: A light tap to top of sensor prior to removal may reduce force needed for removal. 4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on the sensor case, and the O-ring may make removal difficult. INSTALLATION Notes: If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer from the sensor face completely, before attaching new spacer. If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new sensor (Fig. 5). 1. Inspect O-ring for damage, replace if necessary. 2. Ensure the O-ring is positioned in groove of the sensor, and apply a couple drops of clean engine oil to the O-ring prior to installing the sensor (Fig. 7). 3. Install sensor in the chain case cover and push sensor down until contact is made with the camshaft gear. 4. While holding the sensor in this position install and tighten the retaining bolt 14 Nm (125 in-lbs) torque. 5. Connect sensor electrical connector, and position connector away from the accessory belt 6. Install engine mount support bracket. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications NOTE: For information on how this type of sensor operates SEE, Powertrain Management/Computers and Control Systems/Coolant Temperature Sensor/Description and Operation. NOTE: Measure resistance using a high impedance Digital Volt Ohmmeter (DVOM). COLD CURVE (Reference voltage routed to sensor through PCM internal resistance of 10k ohm) Temperature ........................................................................................................................................ ........................................ Voltage -20° F ................................................................................................................................................... ....................................... 4.70 V -10° F ................................................................................................................................................... ....................................... 4.57 V 0° F ...................................................................................................................................................... ...................................... 4.45 V 10° F .................................................................................................................................................... ....................................... 4.30 V 20° F .................................................................................................................................................... ....................................... 4.10 V 30° F .................................................................................................................................................... ....................................... 3.90 V 40° F .................................................................................................................................................... ....................................... 3.60 V 50° F .................................................................................................................................................... ....................................... 3.30 V 60° F .................................................................................................................................................... ....................................... 3.00 V 70° F .................................................................................................................................................... ....................................... 2.75 V 80° F .................................................................................................................................................... ....................................... 2.44 V 90° F .................................................................................................................................................... ....................................... 2.15 V 100° F .................................................................................................................................................. ........................................ 1.83 V 110° F .................................................................................................................................................. ........................................ 1.57 V 120° F .................................................................................................................................................. ........................................ 1.25 V HOT CURVE (Reference voltage routed to sensor through PCM internal resistance of 10 k ohm) Temperature ........................................................................................................................................ ........................................ Voltage 110° F .................................................................................................................................................. ........................................ 4.20 V 120° F .................................................................................................................................................. ........................................ 4.00 V 130° F .................................................................................................................................................. ........................................ 3.77 V 140° F .................................................................................................................................................. ........................................ 3.60 V 150° F .................................................................................................................................................. ........................................ 3.40 V 160° F .................................................................................................................................................. ........................................ 3.20 V 170° F .................................................................................................................................................. ........................................ 3.02 V 180° F .................................................................................................................................................. ........................................ 2.80 V 190° F .................................................................................................................................................. ........................................ 2.60 V 200° F .................................................................................................................................................. ........................................ 2.40 V Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 3112 210° F .................................................................................................................................................. ........................................ 2.20 V 220° F .................................................................................................................................................. ........................................ 2.00 V 230° F .................................................................................................................................................. ........................................ 1.80 V 240° F .................................................................................................................................................. ........................................ 1.62 V 250° F .................................................................................................................................................. ........................................ 1.45 V Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 3113 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Crankshaft Position sensor screw .................................................................................................................................................... 12 Nm (105 in lbs) Camshaft Position sensor screw ...................................................................................................................................................... 12 Nm (105 in lbs) Coolant Sensor .......................................................................................................... .......................................................................... 7 Nm (60 in lbs) Ignition Coil .................................... ................................................................................................................................................ 12 Nm (105 in lbs) Ignition Switch ................................................................................................................... ................................................................. 2 Nm (17 in lbs) Spark Plugs ............................................. ........................................................................................................................................... 28 Nm (20 ft lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3114 Coolant Temperature Sensor/Switch (For Computer): Locations Ignition Coil And Coolant Temperature Sensor Location Sensor mounted under ignition coil. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3117 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3118 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3119 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3120 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3121 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 3122 Coolant Sensor Circuit Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3123 Coolant Temperature Sensor/Switch (For Computer): Description and Operation LOCATION The Engine Coolant Temperature (ECT) sensor is threaded into the intake manifold, next to the thermostat housing. PURPOSE The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle speed, and ignition spark advance. OPERATION The sensor element extends into the coolant passage, where it maintains constant contact with the engine coolant. The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature increases, sensor resistance decreases.) The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below. As sensor resistance changes, the voltage drop across the sensor changes. The PCM translates the voltage drop across the sensor into engine coolant temperature. THEORY As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor (cold operation), or a 909 ohm resistor (warm operation). The resistance circuits are inside the PCM. For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the 10,000 ohm resistor. When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the 909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3124 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Coolant Temperature Sensor Resistance Test 1. With key off, disconnect connector from coolant temperature sensor. 2. Connect ohmmeter across coolant temperature sensor. Resistance should read as follows; - 700 to 1,000 Ohms at approximately 200°F (operating temperature). - 7,000 to 13,000 ohms at approximately 70°F, (room temperature). 3. If resistance is not within specifications, replace sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3125 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Ignition Coil And Coolant Temperature Sensor Location REMOVAL 1. Drain cooling system until coolant level is below sensor. 2. Disconnect coil pack electrical connector to sensor. 3. Remove coil mounting screws. 4. Rotate coil away from coolant temperature sensor. 5. Disconnect electrical connector from coolant temperature sensor. 6. Remove sensor from engine. INSTALLATION 1. Tighten the coolant sensor to 7 Nm (60 in lbs) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. 4. Install coil. Tighten coil mounting screws to 12 Nm (105 in lbs) torque. 5. Connect electrical connector to coil. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3130 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position sensor screw ................................................................................................................................................ 11.9 Nm (105 in lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Crank Position Sensor The Crankshaft Position Sensor is mounted on the transaxle bellhousing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 3133 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3136 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3137 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3138 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3139 Crankshaft Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3140 Crankshaft Position Sensor Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3141 Crankshaft Position Sensor: Electrical Diagrams Crankshaft Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3142 Crankshaft Position Sensor: Description and Operation LOCATION Mounted in transmission housing, above distance sensor. PURPOSE Powertrain Control Module (PCM) uses input to determine basic timing. OPERATION Crankshaft Sensor Driveplate Sensor reads a series of slots cut in transmission driveplate. NOTE: The distance between the sensor and torque converter drive plate is critical to system operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE COMPONENT REPLACEMENT AND REPAIR PROCEDURES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3143 Crankshaft Position Sensor: Service and Repair Fig. 5 Crankshaft Position Sensor Removal 1. Disconnect sensor electrical connector (Fig. 5). 2. Remove sensor retaining bolt. 3. Pull sensor straight up, and out of the transaxle housing. Installation Notes: If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer from the sensor face completely, before attaching new spacer. If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new sensor (Fig. 5). 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. 2. While holding the sensor in this position, install and tighten the retaining bolt to 11.9 Nm (105 in-lbs) torque. 3. Connect sensor electrical connector. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications Vacuum in Inches of Mercury MAP sensor Signal Voltage .39 in Hg .............................................................................................................................................. .............................. 4.90 V 3.34 in Hg ............................................................................................................................................ ............................... 4.60 V 6.30 in Hg ............................................................................................................................................ ............................... 3.60 V 9.25 in Hg ............................................................................................................................................ ............................... 3.10 V 12.20 in Hg .......................................................................................................................................... ................................ 2.60 V 15.15 in Hg .......................................................................................................................................... ................................ 2.10 V 18.11 in Hg .......................................................................................................................................... ................................ 1.60 V 21.06 in Hg .......................................................................................................................................... ................................ 1.10 V 24.01 in Hg .......................................................................................................................................... ................................ 0.60 V 26.97 in Hg .......................................................................................................................................... ................................ 0.31 V Condition ............................................................................................................................................. .................................. Expected Output Voltage High Vacuum (Idle/Deceleration) ............................................................................................................................................................. 0.5 to 1.5 volts Medium Vacuum (Cruise/Slight Acceleration) ......................................................................................................................................... 1.5 to 3.0 volts Low Vacuum (Hard Acceleration/Mechanical Failure) ............................................................................................................................. 3.0 to 4.5 volts NOTE: Any reading of 0 volts or over 5 volts indicates a problem in the MAP sensor circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations Manifold Pressure/Vacuum Sensor: Component Locations Engine Control Component Locations Back Side Of Intake Plenum View Sensor mounted on back side of intake plenum. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations > Page 3149 Back Side Of Intake Plenum View Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions Manifold Pressure/Vacuum Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3152 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3153 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3154 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3155 Manifold Pressure/Vacuum Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3156 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3157 MAP Sensor Circuit Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 3158 Manifold Pressure/Vacuum Sensor: Description and Operation LOCATION Sensor mounted on intake plenum. PURPOSE At start-up, the Powertrain Control Module (PCM) uses sensor to read barometric (atmospheric), pressure, for reference, to calculate air/fuel mixture. During operation the Powertrain Control Module (PCM) monitors sensor input to adjust spark advance and air/fuel mixture. OPERATION PCM supplies 5 volt sensor reference voltage. Sensor, connected to manifold vacuum at throttle body, converts intake manifold pressure into voltage. THEORY Sensor resistance and manifold absolute pressure are inversely proportional (as manifold absolute pressure increases, (low vacuum), sensor resistance decreases and vice versa). OUTPUT VOLTAGES Sensor output voltage range is 0.5 to 4.5 volts. - Output voltages between 0.5 and 1.5 volts indicate a high vacuum situation, such as idle or deceleration. - Output voltages between 1.5 and 3.0 volts indicate a medium level of vacuum such as a cruise or slight acceleration condition. - Output voltages between 3.0 and 4.5 volts indicate a low vacuum situation such as hard acceleration or a mechanical failure. - Any reading of 0 volts or over 5 volts indicates a problem. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 3159 Manifold Pressure/Vacuum Sensor: Testing and Inspection NOTE: To perform a complete test of the Manifold Absolute Pressure (MAP) sensor and its circuitry, refer to appropriate Diagnostic Chart. See: Testing and Inspection TO TEST THE MAP SENSOR ONLY: 1. Inspect the rubber nipple (fitting) from the MAP sensor to the throttle body. Repair as necessary. CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 2. Test the MAP sensor output voltage at the MAP sensor connector terminal 2. With the ignition switch ON, and the engine OFF. Output voltage should be 4 to 5 volts. 3. Test the MAP sensor output voltage at the MAP sensor connector terminal 2 at a hot, neutral idle speed condition. The voltage should drop to 1.5 to 2.1 volts. 4. Test PCM (terminal / pin-5) for the same voltage described above to verify the wire harness condition. Repair as necessary. 5. Test MAP sensor supply voltage at sensor connector terminal 3 with the ignition ON. The voltage should be approximately 5 volts (±O.5 V). 5 volts (±0.5 Volts). should also be present at terminal 6 of the PCM wire harness connector. Repair or replace the wire harness as necessary. 6. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM connector terminal / pin-4. Repair the wire harness if necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 3160 Manifold Pressure/Vacuum Sensor: Service and Repair MAP" Sensor Removal 1. Disconnect vacuum hose and electrical connector from sensor. 2. Remove sensor mounting screws and remove sensor. Installation 1. Install sensor and tighten screws. 2. Connect vacuum hose and electrical connector from sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Air/Fuel Oxygen Exhaust Ratio Sensor Voltage Gas Content 12.0:1 1.0 Volts [1] 5.0% CO [2] 13.0:1 0.85 Volts 3.8% CO [2] 14.0:1 0.65 Volts 1.3% CO [2] 14.7:1 0.45 Volts [5] 0.1% CO [2] 15.0:1 0.35 Volts 2.0% O2 [3] 16.0:1 0.25 Volts 3.0% O2 [3] 17.0:1 0.10 Volts [4] 4.0% O2 [3] Remarks [1] Full rich condition. [2] CO: Carbon monoxide, is a sign of incomplete ignition, (not enough oxygen to burn all the hydrocarbons in cylinder). [3] O2: Oxygen left over after all hydrocarbons have been burned. [4] Full lean condition. [5] Stoichiometric point: Output voltages below 0.45 volts indicate a lean condition, and output voltages over 0.45 volts indicate a rich condition. NOTE: Both lean and rich conditions are usually accompanied by high Hydrocarbon (HC) readings. Due to not enough fuel, (lean misses), or too much fuel, (not enough oxygen to burn all hydrocarbons). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations EGR Mounting Sensor threaded into exhaust manifold, just above flange. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3166 Back Side Of Intake Plenum View Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3169 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3170 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3171 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3172 Oxygen Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3173 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3174 Oxygen Sensor: Electrical Diagrams Oxygen Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3175 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3176 Oxygen Sensor: Description and Operation O2 Sensor Cutaway View (Typical) SENSOR PURPOSE Powertrain Control Module (PCM) uses input to determine whether to enrich or lean air/fuel mixture, during closed loop operation. SENSOR OPERATION The oxygen sensor generates a varying voltage signal dependent upon exhaust gas oxygen content at that point in the exhaust. - Oxygen sensor voltage signal is produced through a galvanic reaction within the sensors. Using the oxygen sensor voltage signal as an air/fuel ratio indicator the PCM can tell how well the system is responding to its output signals. - Changes in the sensor signal occur because the air/fuel ratio is constantly changing. - When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. - When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. Closed Loop During CLOSED LOOP operation, the PCM monitors the signals it receives from the oxygen sensor, and other sensors, and uses these signals to adjust the injector pulse width according to the current driving condition. Open Loop During OPEN LOOP operation, the PCM ignores the oxygen sensor's signals, and other sensor's signals, and adjusts injector pulse widths according to preprogrammed specifications in the PCM. HEATER PURPOSE Vehicle enters CLOSED LOOP faster, (because sensor reaches operating temperature sooner). Allows CLOSED LOOP operation during extended idle, (because heater maintains correct operating temperature). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test Oxygen Sensor: Testing and Inspection Powertrain Control Module Response Test Oxygen Sensor And Connector NOTE: This test should be performed only after the Oxygen Sensor (O2S) has passed the functional test and heating element test. NOTE: A four gas analyzer is needed to perform this test. NOTE: When performing this test it is important that no part of your body contact the vehicle body, as test results will be inaccurate. CAUTION: NEVER apply voltage directly to any computer sensor wire. PRECONDITIONING AND SET UP 1. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T), (to ensure vehicle and oxygen sensor are at operating temperature and vehicle is in closed loop). 2. Turn engine OFF, disconnect the oxygen sensor connector. Connect a jumper lead to the O2S signal wire. 3. Start the engine and run at 2,500 rpm for 1 minute, with the transmission in PARK (A/T), or NEUTRAL (M/T). 4. Let idle. LEAN MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO ENRICH MIXTURE) 1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery negative, hold for 10 to 20 seconds. - The CO and HC readings should increase, as the PCM opens the injectors for longer periods (longer pulse width), to enrich the mixture. 2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or engine control system will be necessary. SEE DIAGNOSIS BY SYMPTOM. RICH MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO LEAN OUT MIXTURE) 1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery positive, hold for 10 to 20 seconds. - The O2 readings should begin to increase, and the CO reading should decrease. 2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or engine control system will be necessary. SEE DIAGNOSIS BY SYMPTOM. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test > Page 3179 Oxygen Sensor: Testing and Inspection Sensor Functional Test Oxygen Sensor And Connector CAUTION: Use a high impedance [1] Digital Volt Ohm Meter (DVOM) ONLY, when testing components on computerized vehicles. 1. Make sure the vehicle is at normal operating temperature. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T). CAUTION: To avoid damaging sensor, voltmeter must be set in Volts mode only, (not ohms). 2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to read DC VOLTS. Disconnect the oxygen sensor ( O2S) electrical connector and connect the positive lead of the DVOM to the oxygen sensor signal wire. 3. Start engine. Create a lean condition for 10 seconds. Voltage should decrease to 0.2 volt or less and remain there. 4. Create a rich condition for 10 seconds. Voltage should increase to 0.8 volt or more and remain there. 5. If sensor fails to vary according to the test steps above, the sensor is defective. 6. Connect sensor and clear codes. Remarks: [1] Minimum 10 Meg (10,000,000) ohm input impedance. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test > Page 3180 Oxygen Sensor: Testing and Inspection Sensor Heating Element Test Oxygen Sensor And Connector Oxygen Sensor Connector Identification And PINOUT 1. Disconnect the Heated Oxygen Sensor (O2S), electrical connector from the wiring harness. 2. Set DVOM to read OHMS. Connect the ohmmeter between the heater feed and heater ground (terminals 3 and 4), of the sensor electrical connector. 3. Resistance should be between 5 and 7 ohms, if not replace the sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Page 3181 Oxygen Sensor: Service and Repair Oxygen Sensor Location (Typical) Oxygen Sensor Socket WARNING: Avoid physical contact with hot exhaust components. CAUTION: Do not pull on or cut sensor wires, when removing sensor. CAUTION: Use of excessive force may damage threads in exhaust manifold or pipe. REMOVAL 1. Disconnect oxygen sensor electrical connector. 2. Using a suitable tool (Snap-On socket YA8875, or equivalent), carefully remove the sensor from exhaust manifold or pipe. (Slightly tightening the sensor before removal may ease removal.) 3. Clean threads in exhaust manifold with an 18 mm X 1.5 + 6E tap. INSTALLATION 1. If a new sensor is being used, verify that the threads are coated with anti-seize compound, before installing in manifold or pipe. 2. If sensor is being reused, coat sensor threads with a nickel based anti-seize compound, (Loctite 771-64 or equivalent). CAUTION: Do not use graphite or other anti-seize compounds. 3. Install sensor, and tighten to 27 Nm (20 ft-lbs). 4. Connect wiring. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts Throttle Position Sensor: Customer Interest TPS - Harsh, Erratic, Or Delayed Transmission Shifts NO: 18-13-94 Rev. A GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Harsh, Erratic or Delayed Transmission Shifts THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 (AS) Caravan/Voyager/Town & Country 1994 (ES) Chrysler Voyager (Export Only) 1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX). SYMPTOM/CONDITION: Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold soak) and during warm-up. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or III) with the appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full range of travel, full open then full closed, and watch the voltage readings. The voltage change should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic voltage change or no voltage change during throttle movement in encountered, particularly when moving the throttle from wide open to closed throttle, proceed with the following repair.** PARTS REQUIRED: 1 4759001 Throttle Position Sensor REPAIR PROCEDURE: This bulletin involves replacing the throttle position sensor with a revised part. 1. Following the proper procedure, remove and replace the throttle position sensor using the new sensor, P/N 4759001. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-10-95 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts Throttle Position Sensor: All Technical Service Bulletins TPS - Harsh, Erratic, Or Delayed Transmission Shifts NO: 18-13-94 Rev. A GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Harsh, Erratic or Delayed Transmission Shifts THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 (AS) Caravan/Voyager/Town & Country 1994 (ES) Chrysler Voyager (Export Only) 1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX). SYMPTOM/CONDITION: Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold soak) and during warm-up. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or III) with the appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full range of travel, full open then full closed, and watch the voltage readings. The voltage change should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic voltage change or no voltage change during throttle movement in encountered, particularly when moving the throttle from wide open to closed throttle, proceed with the following repair.** PARTS REQUIRED: 1 4759001 Throttle Position Sensor REPAIR PROCEDURE: This bulletin involves replacing the throttle position sensor with a revised part. 1. Following the proper procedure, remove and replace the throttle position sensor using the new sensor, P/N 4759001. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-10-95 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3195 Throttle Position Sensor: Specifications THROTTLE POSITION .................................................................................................................................... INCREASE IN TPS VOLTAGE 10° Closed Throttle* ....................................................................................................................................................... 0 volts 20° ....................................................................................................................................................... ........... 0.38 volts 30° ....................................................................................................................................................... ........... 0.75 volts 45° Half Throttle ........................................................................................................................................................ 1.31 volts 58° ....................................................................................................................................................... ......... 1.80 volts** 75° ....................................................................................................................................................... ........ 2.43 volts*** 90° Wide Open Throttle .................................................................................................................................................. 3.00 volts * At idle position the throttle blade is open 10°. The throttle blade is rotated 80° when the throttle is moved from the idle position to the "wide open" position, . ** The PCM recognizes a TPS voltage rise of 1.80 volts or more over idle position voltage as "Wide Open Throttle" (WOT). *** If the TPS voltage sensed at the PCM rises 2.43 volts or more above idle position voltage, the PCM shuts off fuel injection. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Throttle Body View With Idle Air Control Motor Idle Air Control Motor And Throttle Position Sensor Mounted on throttle body. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 3198 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3201 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3202 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3203 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3204 Throttle Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3205 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3206 Throttle Position Sensor: Electrical Diagrams Throttle Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3207 Throttle Position Sensor: Description and Operation PURPOSE PCM uses sensor input with other inputs to determine current operating conditions. PCM adjusts air/fuel mixture (injector pulse width) and ignition timing. OPERATION PCM supplies 5 volt sensor reference voltage. Sensor is a variable resistor (potentiometer), whose resistance is dependent on the angle of the throttle blade (or throttle opening). Output voltage ranges from approximately 0.5 Volts, (at idle position), to approximately 4.0 Volts, (at Wide Open Throttle). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3208 Throttle Position Sensor: Testing and Inspection NOTE: The following procedure tests the TPS only. To perform a complete test of the TPS and its circuitry, SEE Computers and Control Systems/Testing and Inspection/Procedures/Diagnostic Charts/Introduction. PROCEDURE 1. The TPS can be tested with a digital voltmeter. The center terminal of the TPS is the output terminal. 2. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed), and at Wide Open Throttle (WOT). - At idle, TPS output voltage should be approximately 0.5 to 1.0 volt. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. - At wide open throttle, TPS output should be approximately 3.5 volts. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3209 Throttle Position Sensor: Adjustments PROCEDURE - The Throttle Position Sensor on this vehicle is fixed and adjustment is not required. - If sensor output voltage is outside acceptable range, sensor should be replaced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3210 Throttle Position Sensor: Service and Repair Throttle Position Sensor (TPS)/Automatic Idle Speed (AIS) Motor Throttle Position Sensor Removed Removal 1. Disconnect the negative battery cable. 2. Disconnect the Throttle Position Sensor (TPS) wiring connector. 3. Remove the mounting screws (2), and remove the TPS from the throttle shaft. Installation 1. Install the new TPS on the throttle shaft and install screws, torqueing them to 17 in-lbs (2 Nm). 2. Connect the TPS wiring connector. 3. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3219 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3220 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3221 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3227 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3228 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3233 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3234 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3235 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3241 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3242 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 3245 Park Neutral Position Switch / PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 3246 Transmission Position Switch/Sensor: Locations 4 Speed A/T Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 3249 Park / Neutral Position Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 3252 Transmission Position Switch/Sensor: Description and Operation Switch, Transmission Range The white Transmission Range Switch (formerly called PRNDL) is used as an input to the Transmission Control Module, on the 4 speed electronic automatic transaxle. Note: The Transmission Range Sensor is a different component from the Transmission Range Switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 3255 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 3256 Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations Vehicle Speed Sensor: Component Locations This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates vehicle speed based on input received from Input and Output speed sensor mounted on the transaxle. Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 3261 Vehicle Speed Sensor: Connector Locations This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates vehicle speed based on input received from Input and Output speed sensor mounted on the transaxle. Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3264 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3265 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3266 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3267 Vehicle Speed Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3268 Vehicle Speed Sensor: Electrical Diagrams Vehicle Speed Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3269 Vehicle Speed Sensor: Description and Operation This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates vehicle speed based on input received from Input and Output speed sensor mounted on the transaxle. Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts Throttle Position Sensor: Customer Interest TPS - Harsh, Erratic, Or Delayed Transmission Shifts NO: 18-13-94 Rev. A GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Harsh, Erratic or Delayed Transmission Shifts THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 (AS) Caravan/Voyager/Town & Country 1994 (ES) Chrysler Voyager (Export Only) 1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX). SYMPTOM/CONDITION: Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold soak) and during warm-up. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or III) with the appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full range of travel, full open then full closed, and watch the voltage readings. The voltage change should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic voltage change or no voltage change during throttle movement in encountered, particularly when moving the throttle from wide open to closed throttle, proceed with the following repair.** PARTS REQUIRED: 1 4759001 Throttle Position Sensor REPAIR PROCEDURE: This bulletin involves replacing the throttle position sensor with a revised part. 1. Following the proper procedure, remove and replace the throttle position sensor using the new sensor, P/N 4759001. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-10-95 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts Throttle Position Sensor: All Technical Service Bulletins TPS - Harsh, Erratic, Or Delayed Transmission Shifts NO: 18-13-94 Rev. A GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Harsh, Erratic or Delayed Transmission Shifts THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 (AS) Caravan/Voyager/Town & Country 1994 (ES) Chrysler Voyager (Export Only) 1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX). SYMPTOM/CONDITION: Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold soak) and during warm-up. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or III) with the appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full range of travel, full open then full closed, and watch the voltage readings. The voltage change should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic voltage change or no voltage change during throttle movement in encountered, particularly when moving the throttle from wide open to closed throttle, proceed with the following repair.** PARTS REQUIRED: 1 4759001 Throttle Position Sensor REPAIR PROCEDURE: This bulletin involves replacing the throttle position sensor with a revised part. 1. Following the proper procedure, remove and replace the throttle position sensor using the new sensor, P/N 4759001. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-10-95 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3283 Throttle Position Sensor: Specifications THROTTLE POSITION .................................................................................................................................... INCREASE IN TPS VOLTAGE 10° Closed Throttle* ....................................................................................................................................................... 0 volts 20° ....................................................................................................................................................... ........... 0.38 volts 30° ....................................................................................................................................................... ........... 0.75 volts 45° Half Throttle ........................................................................................................................................................ 1.31 volts 58° ....................................................................................................................................................... ......... 1.80 volts** 75° ....................................................................................................................................................... ........ 2.43 volts*** 90° Wide Open Throttle .................................................................................................................................................. 3.00 volts * At idle position the throttle blade is open 10°. The throttle blade is rotated 80° when the throttle is moved from the idle position to the "wide open" position, . ** The PCM recognizes a TPS voltage rise of 1.80 volts or more over idle position voltage as "Wide Open Throttle" (WOT). *** If the TPS voltage sensed at the PCM rises 2.43 volts or more above idle position voltage, the PCM shuts off fuel injection. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Throttle Body View With Idle Air Control Motor Idle Air Control Motor And Throttle Position Sensor Mounted on throttle body. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 3286 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3289 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3290 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3291 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3292 Throttle Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3293 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3294 Throttle Position Sensor: Electrical Diagrams Throttle Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3295 Throttle Position Sensor: Description and Operation PURPOSE PCM uses sensor input with other inputs to determine current operating conditions. PCM adjusts air/fuel mixture (injector pulse width) and ignition timing. OPERATION PCM supplies 5 volt sensor reference voltage. Sensor is a variable resistor (potentiometer), whose resistance is dependent on the angle of the throttle blade (or throttle opening). Output voltage ranges from approximately 0.5 Volts, (at idle position), to approximately 4.0 Volts, (at Wide Open Throttle). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3296 Throttle Position Sensor: Testing and Inspection NOTE: The following procedure tests the TPS only. To perform a complete test of the TPS and its circuitry, SEE Computers and Control Systems/Testing and Inspection/Procedures/Diagnostic Charts/Introduction. PROCEDURE 1. The TPS can be tested with a digital voltmeter. The center terminal of the TPS is the output terminal. 2. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed), and at Wide Open Throttle (WOT). - At idle, TPS output voltage should be approximately 0.5 to 1.0 volt. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. - At wide open throttle, TPS output should be approximately 3.5 volts. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3297 Throttle Position Sensor: Adjustments PROCEDURE - The Throttle Position Sensor on this vehicle is fixed and adjustment is not required. - If sensor output voltage is outside acceptable range, sensor should be replaced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3298 Throttle Position Sensor: Service and Repair Throttle Position Sensor (TPS)/Automatic Idle Speed (AIS) Motor Throttle Position Sensor Removed Removal 1. Disconnect the negative battery cable. 2. Disconnect the Throttle Position Sensor (TPS) wiring connector. 3. Remove the mounting screws (2), and remove the TPS from the throttle shaft. Installation 1. Install the new TPS on the throttle shaft and install screws, torqueing them to 17 in-lbs (2 Nm). 2. Connect the TPS wiring connector. 3. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3307 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3308 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3309 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3315 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3316 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3321 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3322 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3323 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3329 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3330 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 3333 Park Neutral Position Switch / PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 3334 Transmission Position Switch/Sensor: Locations 4 Speed A/T Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 3337 Park / Neutral Position Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 3340 Transmission Position Switch/Sensor: Description and Operation Switch, Transmission Range The white Transmission Range Switch (formerly called PRNDL) is used as an input to the Transmission Control Module, on the 4 speed electronic automatic transaxle. Note: The Transmission Range Sensor is a different component from the Transmission Range Switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 3343 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 3344 Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations Vehicle Speed Sensor: Component Locations This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates vehicle speed based on input received from Input and Output speed sensor mounted on the transaxle. Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component Locations > Page 3349 Vehicle Speed Sensor: Connector Locations This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates vehicle speed based on input received from Input and Output speed sensor mounted on the transaxle. Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3352 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3353 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3354 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3355 Vehicle Speed Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3356 Vehicle Speed Sensor: Electrical Diagrams Vehicle Speed Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3357 Vehicle Speed Sensor: Description and Operation This vehicle does not use a vehicle speed sensor. The Transaxle Control Module (TCM) calculates vehicle speed based on input received from Input and Output speed sensor mounted on the transaxle. Vehicle speed data is sent to the Powertrain Control Module (PCM) on the CCD bus circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Description and Operation Voltage Signal: Description and Operation PURPOSE Supplies Powertrain Control Module (PCM), with current charging system voltage. OPERATION If the PCM senses low battery voltage: - PCM increases injector pulse width to compensate for low voltage. - PCM increases generator field voltage. If the PCM senses high battery voltage: - PCM decreases injector pulse width to compensate for high voltage. - PCM decreases generator field voltage. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 110396 > Jun > 96 > Catalytic Converter - Excessive Sulfur Odor Catalytic Converter: Customer Interest Catalytic Converter - Excessive Sulfur Odor NO: 11-03-96 GROUP: Exhaust EFFECTIVE DATE: June 17, 1996 SUBJECT: Excessive Sulphur Odor MODELS: 1992-1995 (AA) Acclaim/Spirit/LeBaron Sedan 1992-1993 (AC) Dynasty/New Yorker/New Yorker Salon 1992-1993 (AG) Daytona 1992-1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992-1994 (AP) Sundance/Shadow/Shadow Convertible 1993-1995 (AS) Caravan/Voyager/Town & Country NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 2.2L OR 2.5L ENGINES ONLY. SYMPTOM/CONDITION: New catalytic converters are now available to address customer complaints of excessive hydrogen sulfide odor (rotten egg smell) coming from the tailpipe of their vehicles at idle. These catalysts were specially manufactured with a revised internal coating which minimizes sulphur odor. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves the replacement of the catalytic converter with a revised part. Replace the catalytic converter following the repair procedures given in group 11 of the appropriate service manual. POLICY: Reimbursable within the provisions of the warranty, TIME ALLOWANCE: Labor Operation No: 11-50-01-91 0.7 Hrs. FAILURE CODE: P8-New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 110396 > Jun > 96 > Catalytic Converter - Excessive Sulfur Odor Catalytic Converter: All Technical Service Bulletins Catalytic Converter - Excessive Sulfur Odor NO: 11-03-96 GROUP: Exhaust EFFECTIVE DATE: June 17, 1996 SUBJECT: Excessive Sulphur Odor MODELS: 1992-1995 (AA) Acclaim/Spirit/LeBaron Sedan 1992-1993 (AC) Dynasty/New Yorker/New Yorker Salon 1992-1993 (AG) Daytona 1992-1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992-1994 (AP) Sundance/Shadow/Shadow Convertible 1993-1995 (AS) Caravan/Voyager/Town & Country NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 2.2L OR 2.5L ENGINES ONLY. SYMPTOM/CONDITION: New catalytic converters are now available to address customer complaints of excessive hydrogen sulfide odor (rotten egg smell) coming from the tailpipe of their vehicles at idle. These catalysts were specially manufactured with a revised internal coating which minimizes sulphur odor. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves the replacement of the catalytic converter with a revised part. Replace the catalytic converter following the repair procedures given in group 11 of the appropriate service manual. POLICY: Reimbursable within the provisions of the warranty, TIME ALLOWANCE: Labor Operation No: 11-50-01-91 0.7 Hrs. FAILURE CODE: P8-New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3375 Exhaust System - FWD Minivans Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3376 Catalytic Converter: Description and Operation Three Way Catalyst (TWC) PURPOSE Reduces emission of the three major pollutants, (Carbon Monoxide (CO), Hydrocarbon (HC) and Oxides of Nitrogen (NOx)), by up to 90%. OPERATION Oxidation Reaction As exhaust gasses pass through converter, the platinum in the converter triggers an oxidation (burning) reaction. During this process the HC and CO combine with oxygen, forming water vapor (H2O) and Carbon Dioxide (CO2). This process no effect on NOx emissions. Reduction Reaction The Rhodium in the converter converts the NOx into nitrogen and oxygen, in a "reduction" (removal of oxygen), reaction. OPERATING ENVIRONMENT A complete catalytic reaction requires that the air/fuel mixture remains near 14.7:1. This can only be achieved in a properly functioning feedback system with oxygen sensor. The ideal converter operating temperature, for maximum emission reduction and long service life is, 400°C - 800°C (750°F - 1500°F). Engine malfunctions, (for example misfires), can cause temperatures in the converter to excede 1400°C (2500°F), which can melt substrate material. CONSTRUCTION Converter consists of: metal housing, ceramic grid substrate, and catalytic coating, (approximately 2 grams of platinum and rhodium). CAUTION: Never use leaded fuel, as lead compounds tend to coat pores and active material, reducing or eliminating catalyst activity. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3377 Catalytic Converter: Service and Repair Exhaust System - FWD Minivans REMOVAL 1. Remove clamp holding muffler to converter. 2. Remove muffler from converter (it may be necessary to heat the pipe connection). 3. Remove clamp securing converter to header pipe. 4. Remove converter from header pipe (it may be necessary to heat the pipe connection). INSTALLATION 1. Install converter to header pipe with a new clamp. 2. Reposition rear exhaust pipe hanger. 3. Install muffler to converter with a new clamp. 4. Start the engine and inspect for exhaust leaks NOTE: Replace any missing or damaged heat shields. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Service Reminder Indicator Light <--> [Emissions Maintenance Light] > Component Information > Description and Operation Service Reminder Indicator Light: Description and Operation This Emission Maintenance Reminder System is incorporated into the engine controller. The controller stores vehicle mileage into its memory every 8 miles, then at 60,000, 82,500 or 120,000 miles it will illuminate the Emission Maintenance Reminder (EMR) lamp. When the indicated mileage is reached or the EMR lamp is on at all times, the following parts must be replaced and the EMR lamp reset. After necessary emission maintenance has been performed, connect Diagnosis Read-Out Box II (DRB II) to the on-board diagnosis connector. Follow instructions indicated by DRB II tool. 1. At 60,00 miles, proceed as follows: a. Replace EGR valve. b. Clean EGR passage. c. Replace PCV valve. 2. At 82,500 miles, proceed as follows: a. Replace oxygen sensor. 3. At 120,000 miles, proceed as follows: a. Replace EGR valve. b. Clean EGR passage. c. Replace PCV valve. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Component Locations Canister Purge Solenoid: Component Locations EVAP Canister Location Duty Cycle Purge Solenoid Location Solenoid mounted 0n front motor mount, near belts. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Component Locations > Page 3386 Canister Purge Solenoid Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions Canister Purge Solenoid: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3389 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3390 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3391 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3392 Canister Purge Solenoid: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3393 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3394 Evaporative Solenoid Circuit Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Page 3395 Canister Purge Solenoid: Description and Operation Duty Cycle Purge Solenoid Location PURPOSE Powertrain Control Module (PCM) controls timing and rate of purge flow, by varying solenoid pulse width, (the length of time solenoid is energized per cycle). OPERATION PCM controls solenoid by applying and removing solenoid ground. During open loop operation, (including cold start up and hot start time delay), the PCM DE-ENERGIZES the solenoid, preventing EVAP Canister purge. - When the engine enters closed loop, (after warm-up and time delay), PCM ENERGIZES and DE-ENERGIZES solenoid approximately 5 to 10 times per second, depending on operating conditions. NOTE: Solenoid will not operate unless installed correctly. The word TOP should face up when installed. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Page 3396 Canister Purge Solenoid: Testing and Inspection Canister Purge Solenoid/Charcoal Canister Evaporative Canister Location VISUAL INSPECTION 1. Check condition and routing of vacuum hoses. Refer to Vehicle Emission Control Information (VECI) label, (underhood). 2. Ensure all vacuum hoses and electrical wires are clear of exhaust manifold to prevent deterioration. Due to temperature, vacuum hoses should always be a minimum of three inches from exhaust manifold. NOTE: Use only fuel resistant hoses when servicing evaporative emission control system. EVAP CANISTER PURGE SOLENOID TEST 1. Disconnect Solenoid electrical connector, and apply vacuum. Using two jumper wires, energize the solenoid by connecting one of the solenoid terminals to ground, and the other terminal to battery positive. A "click" should be heard as voltage is applied to terminal. - Vacuum should hold when voltage is applied, and bleed off when disconnected. 2. Disconnect jumper wires. 3. Measure resistance between Purge Solenoid terminals. - Resistance should be between 36 and 44 ohms. 4. If solenoid failed any test, replace solenoid. See COMPONENT REPLACEMENT AND REPAIR PROCEDURES. SOLENOID CONTROL CIRCUIT TEST Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Page 3397 1. Disconnect vacuum hose from solenoid to throttle body at throttle body and plug nipple. 2. Connect vacuum pump to open end of hose. 3. Ensure that engine coolant temperature is less than 140° F (60° C). Start engine and allow to idle. 4. Apply 15 in. Hg vacuum and verify that it holds. 5. Increase engine speed to 3000 rpm, verify vacuum is still held. 6. Allow engine to warm up until the coolant temperature is above 158° F (70° C). Increase engine speed to 3000 rpm (within three minutes of starting the vehicle) apply vacuum. Vacuum should not hold. 7. Let engine return to idle and apply 15 in Hg vacuum. Verify that vacuum holds. 8. Allow engine to run longer than 3 minutes and increase speed to 3000 rpm. Apply 15 in. Hg vacuum. Verify that vacuum holds momentarily then bleeds off. NOTE: If solenoid fails any test, check connections, and perform actuation test using scan tool. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Page 3398 Canister Purge Solenoid: Service and Repair Duty Cycle Purge Solenoid Location REMOVAL 1. Remove vacuum hose and electrical connector from solenoid. 2. Depress tab on top of solenoid. Slide the solenoid down and out of bracket. INSTALLATION 1. Slide the solenoid into bracket from the bottom. 2. Connect vacuum hose and electrical connector to solenoid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Description and Operation Evaporative Check Valve: Description and Operation Fuel Tank, Filter, And Chassis Line Routing PURPOSE Prevents fuel system damage, by venting the system in the event of high internal pressure or vacuum. Prevents fuel and vapors from escaping into the atmosphere, (except under extreme conditions, see above). OPERATION Rollover Operation Prevents fuel from escaping, (through the EVAP System), in the event of vehicle rollover, the valve will become inverted. In this position the plunger is forced against the guide plate and raw fuel is prevented from flowing through the valve orifice into the vent tube. Vents excess pressure or vacuum to the atmosphere when calibrated valve setting is exceeded. Pressure Relief Operation One way valve allows fuel and vapors to be vented to the EVAP canister. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Evaporative Emission Control Canister: Locations Evaporative Canister Location EVAP Canister Location Mounted inside right front fender, only the top is visible from engine compartment. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3405 Evaporative Emission Control Canister: Description and Operation EVAP Canister Operation PURPOSE Prevents fuel system damage, by venting the system in the event of high internal pressure or vacuum. Prevents fuel and vapors from escaping into the atmosphere, (except under extreme conditions, see above). OPERATION Under certain conditions, fuel and fuel vapors in the fuel tank expand. When the volume of the tank is exceded, by vapors or fuel and vapors, the overflow is routed, through the pressure relief/rollover valve, to the EVAP canister nipple labeled "Fuel Tank". The vapors are absorbed by the carbon in the canister, and any liquid fuel enters the reservoir in the bottom of the canister, (to protect the carbon bed above). The fuel and vapors are stored in the canister, until the engine is started and certain conditions are met. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3406 Evaporative Emission Control Canister: Testing and Inspection Canister Purge Solenoid/Charcoal Canister Evaporative Canister Location VISUAL INSPECTION NOTE: If Charcoal Canister is saturated with liquid fuel check for proper Purge Shutoff Switch and Pressure/Relief Rollover Valve operation. 1. Check condition and routing of vacuum hoses. Refer to Vehicle Emission Control Information (VECI) label, (underhood). 2. Ensure all vacuum hoses and electrical wires are clear of exhaust manifold to prevent deterioration. Due to temperature, vacuum hoses should always be a minimum of three inches from exhaust manifold. NOTE: Use only fuel resistant hoses when servicing evaporative emission control system. NOTE: The Charcoal Canister and Purge Shutoff Switch are a combined unit and are not serviced separately. If the purge switch or cannister is defective the complete assembly must be replaced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3407 Vapor Canister Hose Connections EVAP CANISTER CONTROL VALVE TEST 1. Disconnect 3/16" vacuum hose from canister and connect a vacuum pump to nipple. 2. Apply 10 inches of vacuum. 3. If valve does not hold vacuum, replace canister. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3408 Evaporative Emission Control Canister: Service and Repair Evaporative Canister Location EVAP Canister Location REMOVAL 1. Remove fuel tubes and vacuum hoses from canister. 2. Remove canister bracket to body bolts. One bolt must be removed from over right front tire. 3. Remove canister and bracket from body. 4. Remove canister to bracket bolt and remove canister from bracket. INSTALLATION 1. Position canister in mounting bracket. 2. Install canister bolt and tighten to 10 Nm (95 in lb). 3. Position canister and bracket to body and install bolts. 4. Tighten bolts to 10 Nm (95 in lb). 5. Install fuel tubes and vacuum hoses on canister. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Electric EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Locations Electric EGR Transducer: Locations EGR Mounting Electric EGR Transducer (EET) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Electric EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Locations > Page 3413 EGR System Mounted near the throttle body. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Electric EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Description and Operation > Backpressure Transducer Operation Electric EGR Transducer: Description and Operation Backpressure Transducer Operation EGR Mounting Electric EGR Transducer (EET) NOTE: The Electric EGR Transducer (EET) assembly is a vacuum control solenoid and a backpressure transducer, in one package. PURPOSE When the solenoid is de-energized the transducer varies the amount of vacuum routed to the EGR valve control nipple, (depending on engine load conditions). OPERATION Transducer is supplied ported vacuum through the solenoid. Transducer is a variable vacuum bleed valve, controlled by exhaust backpressure. When there is no exhaust backpressure, the vacuum bleed valve is completely open, and no vacuum is applied to the EGR valve. - When exhaust backpressure is great enough, it closes the vacuum bleed valve completely, and maximum vacuum is applied to the EGR valve. - When exhaust backpressure is present, but not great enough to close the vacuum bleed valve completely, the vacuum applied to the EGR valve varies with the backpressure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Electric EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Description and Operation > Backpressure Transducer Operation > Page 3416 Electric EGR Transducer: Description and Operation Electric EGR Transducer (EET) Vacuum Control Solenoid Valve Operation EGR Mounting Electric EGR Transducer (EET) NOTE: The EET assembly is a vacuum control solenoid and a backpressure transducer, in one package. PURPOSE The PCM controls when the EGR valve can be actuated, through the solenoid valve portion of the Electronic EGR Transducer (EET). OPERATION Ported vacuum from the throttle body, is supplied to the solenoid valve. The PCM controls the flow of vacuum between the throttle body and the back pressure transducer, (through the solenoid ground circuit). - When the solenoid is energized (grounded), no vacuum is supplied to the transducer. - When the solenoid is de-energized (not grounded), vacuum is supplied to the transducer. The solenoid will always be energized (no EGR), under following conditions: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Electric EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Description and Operation > Backpressure Transducer Operation > Page 3417 - Engine warm-up, (engine coolant temperature below 40 ~F) - Engine at idle - Wide Open Throttle (WOT) operation - Rapid acceleration/deceleration - During EGR system diagnostic check NOTE: If the wiring or connector is disconnected from the solenoid, the EGR valve will operate at all times, (adversely affecting engine idle and performance). Backpressure Transducer Operation EGR Mounting Electric EGR Transducer (EET) NOTE: The Electric EGR Transducer (EET) assembly is a vacuum control solenoid and a backpressure transducer, in one package. PURPOSE When the solenoid is de-energized the transducer varies the amount of vacuum routed to the EGR valve control nipple, (depending on engine load conditions). OPERATION Transducer is supplied ported vacuum through the solenoid. Transducer is a variable vacuum bleed valve, controlled by exhaust backpressure. When there is no exhaust backpressure, the vacuum bleed valve is completely open, and no vacuum is applied to the EGR valve. - When exhaust backpressure is great enough, it closes the vacuum bleed valve completely, and maximum vacuum is applied to the EGR valve. - When exhaust backpressure is present, but not great enough to close the vacuum bleed valve completely, the vacuum applied to the EGR valve Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Electric EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Description and Operation > Backpressure Transducer Operation > Page 3418 varies with the backpressure. Diagnostic Check Operation The solenoid disables the EGR system periodically, to allow the PCM to perform a diagnostic check. - During a diagnostic check, (activated only during select engine/driving conditions), the PCM tests the entire EGR system for failures. - If the PCM detects an EGR system failure, the Malfunction Indicator Lamp (MIL), (previously called the Check Engine Lamp), in the instrument panel will be illuminated, indicating that immediate service is required. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Electric EGR Transducer <--> [EGR Backpressure Transducer] > Component Information > Description and Operation > Page 3419 Electric EGR Transducer: Service and Repair EGR Mounting REMOVAL 1. Disconnect EGR transducer electrical connector and vacuum hose. (Inspect vacuum hose for any damage.) 2. Remove EGR valve to intake manifold bolts. 3. Open transducer clip and remove transducer. 4. Remove EGR valve. 5. Clean gasket surface and discard old gasket. 6. Inspect for signs of leakage or cracks. INSTALLATION 1. Loosely install EGR valve with new gasket. 2. Torque bolts to 200 in lb (22 Nm). 3. Install transducer in clip with orientation tab in slot and snap closed. 4. Connect vacuum hose and electrical connector. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Valve <--> [EGR Control Solenoid] > Component Information > Locations EGR Control Valve: Locations EGR Mounting Electric EGR Transducer (EET) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Valve <--> [EGR Control Solenoid] > Component Information > Locations > Page 3423 EGR System Mounted near the throttle body. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Valve <--> [EGR Control Solenoid] > Component Information > Diagrams > Diagram Information and Instructions EGR Control Valve: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Valve <--> [EGR Control Solenoid] > Component Information > Diagrams > Diagram Information and Instructions > Page 3426 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Valve <--> [EGR Control Solenoid] > Component Information > Diagrams > Diagram Information and Instructions > Page 3427 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Valve <--> [EGR Control Solenoid] > Component Information > Diagrams > Diagram Information and Instructions > Page 3428 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Valve <--> [EGR Control Solenoid] > Component Information > Diagrams > Diagram Information and Instructions > Page 3429 EGR Control Valve: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Valve <--> [EGR Control Solenoid] > Component Information > Diagrams > Diagram Information and Instructions > Page 3430 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Valve <--> [EGR Control Solenoid] > Component Information > Diagrams > Diagram Information and Instructions > Page 3431 EGR Solenoid Circuit Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Valve <--> [EGR Control Solenoid] > Component Information > Description and Operation > Diagnostic Check Operation EGR Control Valve: Description and Operation Diagnostic Check Operation The solenoid disables the EGR system periodically, to allow the PCM to perform a diagnostic check. - During a diagnostic check, (activated only during select engine/driving conditions), the PCM tests the entire EGR system for failures. - If the PCM detects an EGR system failure, the Malfunction Indicator Lamp (MIL), (previously called the Check Engine Lamp), in the instrument panel will be illuminated, indicating that immediate service is required. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Valve <--> [EGR Control Solenoid] > Component Information > Description and Operation > Diagnostic Check Operation > Page 3434 EGR Control Valve: Description and Operation Vacuum Control Solenoid Valve Operation EGR Mounting Electric EGR Transducer (EET) NOTE: The EET assembly is a vacuum control solenoid and a backpressure transducer, in one package. PURPOSE The PCM controls when the EGR valve can be actuated, through the solenoid valve portion of the Electronic EGR Transducer (EET). OPERATION Ported vacuum from the throttle body, is supplied to the solenoid valve. The PCM controls the flow of vacuum between the throttle body and the back pressure transducer, (through the solenoid ground circuit). - When the solenoid is energized (grounded), no vacuum is supplied to the transducer. - When the solenoid is de-energized (not grounded), vacuum is supplied to the transducer. The solenoid will always be energized (no EGR), under following conditions: - Engine warm-up, (engine coolant temperature below 40 ~F) - Engine at idle - Wide Open Throttle (WOT) operation Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Valve <--> [EGR Control Solenoid] > Component Information > Description and Operation > Diagnostic Check Operation > Page 3435 - Rapid acceleration/deceleration - During EGR system diagnostic check NOTE: If the wiring or connector is disconnected from the solenoid, the EGR valve will operate at all times, (adversely affecting engine idle and performance). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair EGR Tube: Service and Repair Fig 6 EGR Tube REMOVAL 1. Remove EGR tube attaching bolts from intake and exhaust manifolds (Fig. 6). 2. Clean intake and exhaust manifold gasket surfaces. Discard old gasket. 3. Check for signs of leakage or cracked surfaces on either manifolds or tube. Repair or replace as necessary. INSTALLATION 1. Loosely assemble EGR tube and new gaskets into place on intake and exhaust manifolds. 2. Tighten mounting bolts to 22 Nm (200 in lb) torque. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations EGR Valve: Locations EGR Mounting Valve and transducer, mounted near throttle body. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 3442 EGR Valve: Service and Repair EGR Mounting REMOVAL 1. Disconnect EGR transducer electrical connector and vacuum hose. (Inspect vacuum hose for any damage.) 2. Remove EGR valve to intake manifold bolts. 3. Open transducer clip and remove transducer. 4. Remove EGR valve. 5. Clean gasket surface and discard old gasket. 6. Inspect for signs of leakage or cracks. INSTALLATION 1. Loosely install EGR valve with new gasket. 2. Torque bolts to 200 in lb (22 Nm). 3. Install transducer in clip with orientation tab in slot and snap closed. 4. Connect vacuum hose and electrical connector. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Fillpipe Restrictor > Component Information > Description and Operation Fillpipe Restrictor: Description and Operation Fill Pipe Restrictor PURPOSE Prevents the addition of leaded fuel, which would coat the oxygen sensor, and catalytic converter with lead. Flapper controls evaporation of fuel during the time the filler cap is removed. OPERATION The smaller fill pipe center opening prevents leaded fuel nozzles from be inserted. INSPECTION Use dowel gauge to check opening. Look for; tampering, broken flapper, excessive wear etc.. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Positive Crankcase Ventilation Valve: Locations Back Side Of Intake Plenum View Mounted on back side of intake plenum. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3450 Positive Crankcase Ventilation Valve: Testing and Inspection PCV System NOTE: Perform both checks if there is a problem suspected in the PCV system. With Engine Idling, Check for Vacuum at Valve 1. Remove PCV valve from rocker cover, a hissing sound should be heard. 2. Place a finger over the inlet of the valve, a strong vacuum should be felt. 3. Install the PCV valve, then remove crankcase inlet air cleaner. With engine idling, loosely hold a piece of stiff paper (such as a parts tag) over the opening in the rocker arm cover. After allowing about a minute for the crankcase pressure to reduce, the paper should be drawn against the opening in the rocker arm cover. 4. If the paper is not drawn against the crankcase inlet air cleaner opening with considerable force, check the PCV valve, the passage in the throttle body and the PCV hose for restrictions. With Engine Off, Check for Valve Movement 1. Remove and shake the PCV valve, a rattling noise should be heard, (valve is not stuck). DIAGNOSIS - If A strong vacuum is felt and the PCV valve rattles, the system is operating properly and no further testing is necessary. - If no vacuum is felt and the PCV valve rattles, then the intake plenum and/or the crankcase vent hoses need to be cleaned or replaced. (Do not attempt to clean valve). - If PCV valve does not rattle when shook, replace valve. (Do not attempt to clean valve). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations Fig 1 Intake Plenum Mounting Bolts Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fig 1 Intake Plenum Mounting Bolts Fuel Pressure Release Procedure - Typical WARNING: The fuel system is under constant pressure of approximately 48 psi (330 kPa), even when the engine is OFF. 1. Disconnect negative battery cable. 2. Loosen fuel tank filler cap to relieve fuel tank pressure. 3. Remove cap on fuel rail pressure test port (Fig. 1). 4. Place one end of fuel pressure release hose, tool C-4799-1 (or equivalent), in an approved gasoline container. Connect the other end of this hose to the fuel rail service port. Fuel pressure should bleed off into container. 5. Perform necessary fuel system service procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications NOTE: Idle speed is not adjustable. Powertrain Control Module (PCM) controls idle speed through Idle Air Control (IAC) Motor. If idle speed is outside of specifications, or is rough, or unstable, inspect and clean throttle body, (if deposits are visible). After cleaning throttle body perform minimum air flow test. SEE DIAGNOSIS, TESTING AND INSPECTION PROCEDURES MINIMUM AIRFLOW TEST IDLE SPEED ODOMETER READING IDLE SPEED Less than 1000 miles 525-875 RPM More than 1000 miles 575-875 RPM Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3462 Idle Speed: Adjustments CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle speed using this screw, unless directed to do so in a service procedure. Idle speed is electronically controlled by the Powertrain Control Module (PCM) through the Idle Air Control (IAC) motor, and is not adjustable. If idle is outside of specified RPM, or is rough, or unstable, inspect and clean throttle body if deposits are visible. Perform Minimum Idle Air Flow Test if applicable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Specifications Air/Fuel Mixture: Specifications The Air/Fuel Ratio is controlled by the Powertrain Control Module (PCM) and is not adjustable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Specifications > Page 3466 Air/Fuel Mixture: Adjustments CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle mixture using this screw! Idle mixture is electronically controlled by the Powertrain Control Module (PCM), and is not adjustable. If an idle mixture problem is suspected, check oxygen sensor and feedback system. SEE Computers and Control Systems. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Idle Air Control Motor - Whistling Noise Auxiliary Air Valve (Idle Speed): Technical Service Bulletins Idle Air Control Motor - Whistling Noise NO.: 14-09-93 Rev.A GROUP: Fuel DATE: Nov. 12, 1993 SUBJECT: Idle Air Control Motor Whistle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NO. 14-09-93 DATED 6-4-93, WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. CHANGES INCLUDE MODELS & DIAGNOSIS REVISION. MODELS: ** 1991 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon (AY) Imperial/New Yorker Fifth Avenue 1991 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country** 1993 (LH) Concorde/Intrepid/Vision 1994 (LH) LHS/New Yorker **NOTE: THIS BULLETIN APPLIES TO 3.3L & 3.8L AC & AY; 3.3L AS BUILT PRIOR TO MDH 1108XX; AND LH MODELS BUILT PRIOR TO MDH 0726XX.** SYMPTOM/CONDITION: Vehicle exhibits a high-pitched whistling noise from the engine compartment at idle. The noise may be more prevalent when the engine is under a load such as air conditioning or headlamps on. No whistling can be heard while cruising. DIAGNOSIS: **Place the gear selector in park, set the parking brake, and start the engine. Let the engine idle for several minutes (3 to 5 minutes). Verify there are no vacuum leaks in the engine compartment. Increase the engine RPM's to around 1200 using the throttle. If the whistle sound goes away, perform the repair procedure below. If the whistle does not go away see Technical Service Bulletin No. 21-01-93 published 1-13-93.** PARTS REQUIRED: 1 4612673 Idle Air Control Motor REPAIR PROCEDURE: This bulletin involves the replacement of the idle air control motor. 1. Using the procedures outlined in the appropriate Service Manual, replace the idle air control motor. 2. Run the engine at idle to verify the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 14-30-23-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fillpipe Restrictor > Component Information > Description and Operation Fillpipe Restrictor: Description and Operation Fill Pipe Restrictor PURPOSE Prevents the addition of leaded fuel, which would coat the oxygen sensor, and catalytic converter with lead. Flapper controls evaporation of fuel during the time the filler cap is removed. OPERATION The smaller fill pipe center opening prevents leaded fuel nozzles from be inserted. INSPECTION Use dowel gauge to check opening. Look for; tampering, broken flapper, excessive wear etc.. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications Fuel: Specifications FUEL REQUIREMENTS The vehicle is designed to meet all emission regulations and provide excellent fuel economy when using high quality unleaded gasoline having a minimum octane rating of 87. The vehicle will operate on fuels ranging from regular unleaded having a minimum posted octane of 87 to premium unleaded with a minimum posted octane of 91. However, mid-grade unleaded fuel with a minimum octane rating of 89 is recommended. The use of premium unleaded gasoline will further improve performance. If the vehicle develops occasional light spark knock (ping) at low engine speeds this is not harmful. However; continued heavy spark knock at high speeds can cause damage and should be corrected immediately. Engine damage as a result of heavy spark knock operation may not be covered by the new vehicle warranty. In addition to using unleaded gasoline with the proper octane rating, those that contain detergents, corrosion and stability additives are recommended. Using gasoline that has these additives will help improve fuel economy, reduce emissions, and maintain vehicle performance. Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. If you experience these problems, try another brand of gasoline before considering service for the vehicle. ADDITIVES & OXYGENATE BLENDS Additives - The use of gasoline containing detergents, corrosion and stability additives is recommended, as these additives will improve fuel economy, reduce emissions, and maintain vehicle performance. Fuel Quality - Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. If you experience these problems, try another brand of gasoline before considering service for the vehicle. Pinging/Knocking - Light knock at low engine speeds is not harmful to your engine. However, continued heavy spark knock at high speeds can cause damage and should be reported to your dealer immediately. CAUTION: Engine damage resulting from operating with a heavy spark knock may not be covered by the new vehicle warranty. GASOLINE/OXYGENATE BLENDS Ethanol - (Ethyl or Grain Alcohol) properly blended, is used as a mixture of 10 percent ethanol and 90 percent gasoline. Gasoline blended with ethanol may be used in your vehicle. Methanol - (Methyl or Wood Alcohol) is used in a variety of concentrations when blended with unleaded gasoline. You may find fuels containing 3 percent or more methanol along with other alcohols called cosolvents. CAUTION: Do not use gasoline containing Methanol. Use of methanol/gasoline blends may result in starting and driveability problems and damage critical fuel system components. Problems that are the result of using methanol/gasoline blends may not be covered by the new vehicle warranty. CLEAN AIR GASOLINE MTBE/ETBE - Many gasoline are now being blended that contribute to cleaner air, especially in those areas of the country where pollution levels are high. These new blends provide a cleaner burning fuel and some are referred to as reformulated gasoline.. MTBE (Methyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline and up to 15 percent MTBE. Gasoline blended with MTBE may be used in your vehicle. ETBE (Ethyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline and up to up to 17 percent ETBE. Gasoline blended with ETBE may be used in your vehicle. ADDITIVE CAUTION: Many materials intended for gum and varnish removal may contain active solvents or similar ingredients that can be harmful to fuel system gasket and diaphragm materials. Indiscriminate use of fuel system cleaning agents should be avoided. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Specifications Fuel Filler Cap: Specifications Pressure Vent Limit ............................................................................................................................. ................................................ 1.5 psi (10 kPa) Vacuum Vent Limit ................................................... ........................................................................................................................ 1.8 in-Hg (6 kPa) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Specifications > Page 3480 Fuel Filler Cap: Description and Operation The filler cap is also a pressure/vacuum relief valve, which opens whenever pressure in the tank gets either too low or too high. Filler cap venting pressures: - Pressure above 10.9 to 13.45 kPa (1.58 to 1.95 psi) - Pressure below 0.97 and 2.0 kPa (0.14 and 0.29 psi) Only filler caps with these specifications may be used as replacements. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fig 1 Intake Plenum Mounting Bolts Fuel Pressure Release Procedure - Typical WARNING: The fuel system is under constant pressure of approximately 48 psi (330 kPa), even when the engine is OFF. 1. Disconnect negative battery cable. 2. Loosen fuel tank filler cap to relieve fuel tank pressure. 3. Remove cap on fuel rail pressure test port (Fig. 1). 4. Place one end of fuel pressure release hose, tool C-4799-1 (or equivalent), in an approved gasoline container. Connect the other end of this hose to the fuel rail service port. Fuel pressure should bleed off into container. 5. Perform necessary fuel system service procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations Fuel Injector: Locations Fuel Rail Removal And Replacement (Intake Plenum Removed) The fuel injectors are attached to the fuel rail which mounts to the lower intake manifold under the air intake plenum. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Page 3488 Fuel Injector: Description and Operation Fuel Injector - Cutaway View PURPOSE Enables PCM to compensate for varying engine operating conditions by controlling the amount of fuel injected, precisely. - Atomizes fuel for more complete combustion. - Sprays fuel into intake manifold, above intake ports, in an even, conical pattern. OPERATION When an injector solenoid is energized, the plunger is retracted, lifting needle valve off seat, allowing the pressurized fuel to spray into the intake manifold. When the solenoid is de-energized spring pressure closes valve. Since the injector nozzle is a fixed size and fuel pressure is regulated (at 48 psi), the amount of fuel injected changes only when the amount of time the injector is energized per cycle changes. (This period of time is called "injector pulse width".) . Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Cleaning Procedure Fuel Injector: Service and Repair Fuel Injector Cleaning Procedure Follow purge system manufacturer's instructions for injector purge procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Cleaning Procedure > Page 3491 Fuel Injector: Service and Repair Fuel Injector Replacement Fuel Injector Removed Fuel Injector Installation WARNING: The fuel system is under constant pressure, even when the engine is OFF. Always release fuel pressure before servicing any fuel system component. REMOVAL 1. Release fuel system pressure. 2. Disconnect the negative battery cable and remove the fuel rail. 3. Disconnect the wiring connector from the fuel rail to the injector. 4. Remove the fuel injector lock clip, and slide the injector straight out of the fuel rail cup. 5. Check each injector O-ring for damage and replace any damaged O-rings prior to installation. If the injector is to be re-used, place a protective cap over the injector tip, while it is removed. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Cleaning Procedure > Page 3492 INSTALLATION 1. Before installing injectors lubricate the O-ring with a drop of engine oil. 2. For each injector, install injector top into fuel rail cup, and install injector lock clip by sliding open end into injector slot, and onto the fuel rail cup side slots. 3. Install injector electrical connectors. 4. Install fuel rail. 5. Using scan tool [1], activate fuel pump and pressurize system. 6. Check for leaks. Remarks [1] Follow scan tool manufacturer's instructions. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Check Valve > Component Information > Description and Operation Fuel Pressure Check Valve: Description and Operation Fuel Tank, Filter, And Chassis Line Routing PURPOSE Prevents fuel system damage, by venting the system in the event of high internal pressure or vacuum. Prevents fuel and vapors from escaping into the atmosphere, (except under extreme conditions, see above). OPERATION Rollover Operation Prevents fuel from escaping, (through the EVAP System), in the event of vehicle rollover, the valve will become inverted. In this position the plunger is forced against the guide plate and raw fuel is prevented from flowing through the valve orifice into the vent tube. Vents excess pressure or vacuum to the atmosphere when calibrated valve setting is exceeded. Pressure Relief Operation One way valve allows fuel and vapors to be vented to the EVAP canister. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations Fuel Pressure Regulator: Locations Fuel Pressure Regulator Installed The fuel pressure regulator is mounted on the fuel rail. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 3499 Fuel Pressure Regulator: Description and Operation Fuel Pressure Regulator PURPOSE The fuel pressure regulator is used to maintain a constant pressure of 4 psi in the fuel supply system. OPERATION The pressure regulator uses a vacuum assisted spring loaded diaphragm to control the fuel return port in order to maintain constant pressure. Pressurized fuel is delivered to the fuel rail and then flows through the injectors or the pressure regulator. When fuel pressure acting on the regulator diaphragm exceeds 48 psi, the regulator spring is compressed and the fuel return port is opened. - When fuel pressure drops below 48 psi, spring tension causes the diaphragm to block the fuel return port. As manifold vacuum increases during deceleration, less pressure is needed to supply the same amount of fuel into the air flow. In order to fine tune the fuel pressure under all operating conditions, the vacuum assists in opening the fuel port during high vacuum conditions. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 3500 Fuel Pressure Regulator: Adjustments No adjustments available for the fuel system pressure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 3501 Fuel Pressure Regulator: Service and Repair Fuel Pressure Regulator Installed WARNING: The fuel system is under constant pressure, even when the engine is OFF. Always release fuel pressure before servicing any fuel system component. REMOVAL 1. Release fuel system pressure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Remove the fuel pressure regulator vacuum connector. 3. Remove regulator retaining screw and remove regulator retainer. Position a shop towel under regulator to catch any fuel spilled when regulator is removed. Fuel Pressure Regulator Removal 4. Remove fuel pressure regulator. INSTALLATION 1. Be sure that the fuel pressure regulator has 2 plastic spacers and that there are 2 O-rings in the fuel rail before installing the regulator.. Press regulator into fuel rail. Place retainer with screw over regulator and torque retainer screw to 7 Nm (60 in-lbs). 2. Connect fuel pressure regulator vacuum hose and negative battery cable. 3. Using scan tool [1], activate fuel pump and pressurize system. 4. Check for leaks. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 3502 Remarks [1] Follow scan tool manufacturer's instructions. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations Fig 1 Intake Plenum Mounting Bolts Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Locations Fuel Pressure Pulsation Damper: Locations Fuel Rail The fuel pressure dampener is located on the fuel rail opposite the fuel pressure regulator. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Locations > Page 3509 Fuel Pressure Pulsation Damper: Description and Operation Fuel Pressure Dampener The fuel pressure dampener, located downstream from the fuel pressure regulator, damps fuel pressure pulsations at the injectors caused by the opening and closing of the injectors. The dampener is an internal rubber diaphragm with a pocket of air behind it. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations Fig 1 Intake Plenum Mounting Bolts Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center (Relay Locations) Fuel Pump Relay Socket Fuel pump relay is located in LH side of engine compartment in the power distribution center. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3518 Fuel Pump Relay: Description and Operation Relay Locations PURPOSE Relay supplies battery voltage to the fuel pump and oxygen sensor heater element, when grounded by the Powertrain Control Module (PCM). OPERATION The PCM grounds the relay when the ignition switch is in the START or RUN position and the PCM is receiving reference signals from the distributor pick-up. If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM interrupts the relay ground and no voltage is supplied to the fuel pump and oxygen sensor heater element. NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through the same ground circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3519 Fuel Pump Relay: Testing and Inspection NOTE: The relay terminal numbers can be found on the bottom of the relay: TERMINAL IDENTIFICATION - Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times. ^ Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the component being operated. - Terminal number 86 is connected to a switched (+) power source. - Terminal number 85 is grounded by the PCM. PROCEDURE 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value (ohms) should be 75 ± 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 Volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. Continuity should now be present between terminals number 87 and 30. Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 Volt power source. - If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring Diagrams for fuel system wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Locations Fuel Rail: Locations Fuel Rail Bolt Location (Intake Plenum Removed) The fuel rail assembly is mounted beneath the intake manifold, on top of the engine. The intake manifold must be removed to access the fuel rail. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Locations > Page 3523 Fuel Rail: Description and Operation Fuel Rail The fuel rail is a steel distribution pipe with mounting points for the fuel pressure regulator, 6 fuel injectors, and injector wire harness. The fuel rail performs the dual functions of fuel supply to the injection components, and providing the necessary brackets and fittings to mount the components to the engine. Fuel enters the fuel rail at the inlet tube, proceeds to the 6 fuel injectors and fuel pressure regulator, and returns to the tank via the fuel return line. The fuel rail is under constant fuel pressure and fuel pressure release is required prior to servicing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Locations > Page 3524 Fuel Rail: Service and Repair WARNING: The fuel system is under constant pressure, even when the engine is OFF. Always release fuel pressure before servicing any fuel system component. REMOVAL 1. Release fuel system pressure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Disconnect negative battery cable, and remove air cleaner to throttle body hose. 3. Remove throttle cable. Remove wiring harness from the throttle cable bracket and intake manifold water tube. 4. Remove Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors from throttle body. Remove vacuum hose harness from throttle body, and PCV and brake booster hoses from air intake plenum. 5. Remove wiring connector from charge temperature sensor. Remove EGR tube flange and vacuum connections from intake plenum. Remove fuel hoses from fuel rail. See Powertrain Management/Fuel Delivery and Air Induction/Service and Repair. Quick Connect Fittings 6. Remove intake plenum to cylinder head strut. Disconnect oxygen sensor connector, Manifold Absolute Pressure (MAP) sensor connector and engine ground strap. 7. Remove the Direct Ignition System (DIS) coils and generator to intake manifold bracket bolt. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Locations > Page 3525 Intake Manifold Bolt Location 8. Remove all 4 intake plenum to intake manifold fasteners, and move plenum back over the rear valve cover. Cover intake manifold ports before proceeding. 9. Disconnect fuel pressure regulator vacuum harness. Remove fuel tube retainer bracket and fuel rail attaching bolts. 10. Spread retainer brackets and remove injector wiring clip from the generator bracket. Fuel Rail Bolt Location (Intake Plenum Removed) 11. Disconnect cam sensor, coolant temperature sensor and engine temperature sensor connectors. 12. Remove fuel rail, using care to avoid damaging injectors or injector O-rings. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Locations > Page 3526 Fuel Rail Removal INSTALLATION 1. Make sure injectors are seated into fuel rail receiver cups, and injector lock clips are in place. Check injector holes to make sure they are clean and any plugs have been removed. Lube injector O-rings with clean engine oil prior to installation. 2. Place the tip of each injector in its respective port and push the rail assembly into place until all injectors are seated in the ports. Install the fuel rail attaching bolts and torque to 22 Nm (200 in-lbs). 3. Install the fuel tube retaining bracket and torque to 4 Nm (35 in-lbs). 4. Connect cam sensor, coolant temperature sensor and engine temperature sensor. Install injector wiring harness clips to the generator bracket and intake manifold water tube. 5. Connect fuel pressure regulator vacuum hose. Remove covering from intake manifold, and clean surface. 6. Place intake manifold gaskets on lower manifold. Install intake plenum and hand tighten fasteners. 7. Install the generator bracket to intake manifold bolt, and the cylinder head to intake manifold strut bolts, (do not torque at this time). Intake Manifold Bolt Location 8. Torque intake manifold bolts to 28 Nm (250 in-lbs). Follow torque sequence in image above. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Locations > Page 3527 9 Torque generator bracket to intake manifold, and cylinder head to intake manifold bolts to 54 Nm (40 ft-lbs). 10. Connect ground strap, MAP sensor, charge temperature sensor and oxygen sensor connectors. 11. Install DIS coils and torque bolts to 12 Nm (105 in-lbs). 12. Connect fuel lines to fuel rail and torque clamps to 1 Nm (10 in-lbs). Connect vacuum harness to air intake plenum and fuel pressure regulator. 13. Connect brake booster supply hose to intake plenum and connect PCV hose to plenum. Connect IAC motor and TPS electrical connectors, and connect vacuum harness to throttle body. 14. Install throttle cable, and air inlet hose assembly. Connect negative battery cable. NOTE: ASD and fuel pump relays remain energized for 7 minutes during the following test, unless the test is stopped or the ignition switch is turned to the OFF position. 15. Using scan tool, place ignition switch in "RUN" position and use Actuate Output Test "Auto Shutdown (ASD) Relay", to activate fuel pump and pressurize system. 16. Check for leaks. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation > Fuel Tank/Lines/Filler Operation Fuel Return Line: Description and Operation Fuel Tank/Lines/Filler Operation Hoses The hoses used on fuel injected models are of a special type and only hoses marked EFI/EFM may be used as replacements. Fittings and Clamps There are two ways that the fuel lines are attached to various fuel system components. - The first way is with a rolled edge type clamp (the purpose of the rolled edge is to prevent the clamp from cutting the fuel hoses). Quick Connect Fuel Fitting Assembly - The second type of fitting is called a Quick-Connect fuel fitting. These fittings consist of internal O-rings, a metal locking retainer, and a plastic release collar to disconnect the fitting from the fuel tube. No-Lead Filler Tube All catalyst equipped models have a special filler tube. The filler tube also contains a deflector to prevent the addition of fuel by other than an unleaded fuel nozzle. "Unleaded Fuel Only" Labels are attached at the instrument panel and near the fuel door, to remind the operator. Pressure/Vacuum Filler Cap The loss of liquid fuel or vapor is prevented by using a filler cap which releases under 10.9 to 13.45 kPa (1.58 to 1.95 psi). Only caps with these specifications may be used as replacements to maintain the integrity of the fuel system. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation > Fuel Tank/Lines/Filler Operation > Page 3532 Fuel Return Line: Description and Operation Quick Connect Fuel Fittings Operation Disassembly Quick Connect Fuel Fittings Notes: Some fuel lines have quick connect fittings, which are designed to speed up the installation and removal of fuel lines (Fig. 3). Quick connect fittings consist of a metal casing, a black plastic release ring, a metal locking retainer, and internal O-rings. Warning: Fuel system pressure must be released before disconnecting any fuel system component. 1. Disconnect the negative battery cable. 2. Remove the fuel tank gas cap to release fuel tank pressure. 3. Perform the Fuel System Pressure Release Procedure. 4. Remove any loose dirt from quick connect fittings. CAUTION: Wrap shop towels around hoses to catch any gasoline spillage. 5. To remove the fuel tube nipple from a quick connect fitting, pull back on the fitting while pushing in on the plastic ring. To aid in disassembly, an open end wrench may be used to push the plastic ring in. 6. Cover the quick connector to prevent contamination. Assembly 1. Inspect the quick connect fitting to ensure the black plastic release ring is in the OUT position. If the locking retainer is stuck in the RELEASE position, due to mushrooming of the release ring or dirt accumulation, the fitting should be replaced. CAUTION: The fuel tube nipples must be lubricated with clean 30 weight engine oil prior to connecting the quick-connect fitting. 2. Lubricate the male end of the fuel tube with 30 weight engine oil. 3. Insert fuel tube nipple into quick connector fitting. When the fuel tube nipple is inserted into the quick-connect fitting, the shoulder of the nipple is locked in place by the locking retainer and the internal O-rings seal the tube. 4. Pull back on the quick connect fitting to verify the connection is secure. The tube should be locked in place. If the connection is not complete, make sure the black plastic release is not causing the locking retainer to jam in the release position. CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off position. 5. Using a scan tool, activate the ASD relay, to pressurize the fuel system, and check for leaks. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hoses and Clamps Fuel Return Line: Service and Repair Fuel Hoses and Clamps NOTE: Fuel injected vehicles use specially constructed hoses. When replacing hoses, only use hoses marked EFM/EFI. 1. Inspect all hose connections (clamps and quick connect fittings) for completeness and leaks. Replace cracked, scuffed, or swelled hoses. Replace hoses that rub against other vehicle components or show sign of wear. 2. When installing FUEL hoses: - Ensure that they are routed away from contact with other vehicle components that could rub against them and cause failure. - Avoid contact with clamps or other components that cause abrasions or scuffing. Ensure that rubber hoses are properly routed and avoid heat sources. - Use only original equipment or equivalent hose clamps, which have rolled edges to prevent the clamp from cutting the hose. Other types of clamps may cut into the hoses and cause high pressure fuel leaks. Tighten hose clamps to 1 N-m (10 in lbs) torque. - For replacement SEE QUICK-CONNECT FITTING REPLACEMENT. See: Service and Repair/Quick-Connect Fitting Replacement Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hoses and Clamps > Page 3535 Fuel Return Line: Service and Repair Quick-Connect Fitting Service With Retainer Ring Type Fittings Quick Connect Fitting (Chassis Fuel Tubes) Quick Connect Fitting Assembly/Disassembly (Chassis Fuel Tubes) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hoses and Clamps > Page 3536 Fuel Line Quick Connect Fitting NOTE: Plastic ring type quick connect fittings are not serviced separately. Do not attempt to repair damaged quick connect fittings or tubes. Replace complete fuel tube/quick connect fitting assembly. Quick Connect Fittings REMOVAL 1. Disconnect negative battery cable. 2. Perform fuel pressure release procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hoses and Clamps > Page 3537 3. Push the fitting toward the component being serviced while pushing the plastic retainer ring into the fitting. 4. With the ring depressed, pull the fitting from the component. An open-end wrench may be used to assist in unlocking the fittings. The retainer should remain on the fitting. NOTE: The retainer must be pressed squarely into the fitting. If the retainer is cocked it will be difficult to disconnect fitting. 5. While fuel lines are disconnected, plug the lines so that dirt and foreign particles do not enter the lines. 6. Inspect the fitting and connector, and replace as needed. INSTALLATION NOTE: Before reassembling the Quick-Connect fittings, clean with a lint free cloth and lubricate the fuel tube nipples with clean engine oil. CAUTION: Never install quick connect fitting if retainer ring is damaged or stuck in the release position. 1. Check that the black plastic ring is in the OUT position. If the release ring is stuck in the release position due to dirt accumulation or mushrooming of the release ring, the fitting should be replaced. 2. Push the fuel tube into the connector until a click is felt. Check the connection by pulling back lightly on the fuel tube (15 to 30 lbs). It should remain inside the connector, locked in place. With Single TAB Type Fittings Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hoses and Clamps > Page 3538 Quick Connect Fitting Assembly/Disassembly (Except Chassis Fuel Tubes) MANUAL REMOVAL 1. Bend the retainer tabs down. 2. While pulling up on the underside of the retainer tab, push the legs of the retainer clip away from each other. 3. Raise the pull tab until the hooks on the legs of the retainer clip clears the fuel tube. 4. Pull fuel tube out of the Quick-Connect fitting. 5. Check the connector body and retainer for damage. Replace if necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hoses and Clamps > Page 3539 Disconnecting Quick Connect Fittings (Screwdriver) REMOVAL USING SCREWDRIVER 1. Bend the retainer tabs down. 2. Insert a screwdriver between the retainer clips pull tab and the body of the Quick-Connect fitting. 3. Rotate the screwdriver 90 degrees to lift the retainer clip. 4. Raise the pull tab while pushing the legs of the retainer clip away from each other. 5. Raise the retainer clip until the hooks on the legs of the retainer clip clears the fuel tube. 6. Pull fuel tube out of the Quick-Connect fitting. 7. Check the connector body and retainer for damage. Replace if necessary. Quick Connect Fuel Fitting INSTALLATION Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hoses and Clamps > Page 3540 1. Before installing the fuel tube into Quick-Connect fitting, clean the fuel tube and lubricate the nipple with new engine oil. 2. Push fuel tube into Quick-Connect fitting until the stop on the fuel tube rests against the back of the Quick-Connect fitting. 3. Push the retainer clip into the slot in the Quick-Connect fitting until it locks in place. 4. Bend the retainer clip tabs up into their locking position. CAUTION: The fuel system remains pressurized after engine has been shut off. Release system pressure prior to opening system. WARNING: Gasoline is extremely volatile, when servicing fuel systems always wear eye protection, keep open flame away from fuel system components, and prohibit smoking in service areas. NOTE: Wrap shop towels around fuel hoses to absorb any fuel that spills during fuel tank replacement With Two TAB Type Fittings NOTE: Fuel injection quick connect fittings are not serviced separately. Do not attempt to repair damaged quick connect fittings or tubes. Replace complete fuel tube/quick connect fitting assembly. REMOVAL Fuel Line Quick Connect Fitting Fuel Line Quick Connect Fitting 1. Disconnect negative battery cable. 2. Perform fuel pressure release procedure. 3. Squeeze retainer tabs together and pull quick connect fitting off fuel tube nipple. The retainer will remain on fuel tube. INSTALLATION 1. Using a clean lint free cloth, clean fuel tube nipple and retainer. 2. Using a clean motor oil, lightly lube nipple and retainer. CAUTION: Never install quick connect fitting if retainer is damaged or missing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Hoses and Clamps > Page 3541 Fuel Line Quick Connect Fitting 3. Push fitting over fuel tube until retainer seats and a click is heard. When the fitting is properly locked retainer ears will be visible in the windows. 4. Verify connection by pulling on the fuel tube. If fitting locks in place connection is secure. 5. Using the DRB II select the Automatic Shut Down (ASD) Fuel System Test to pressurize fuel system and check for leaks. Refer to Powertrain Management/Computers and Control Systems/Testing and Inspection/Procedures CAUTION: Unless the test is stopped or the ignition switch is turned to the OFF position the fuel pump relay and the ASD relay will remain energized for 7 minutes by the ASD Fuel System Test Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Locations Fuel Supply Line: Locations Fuel Tank Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Locations > Page 3545 Fuel Tank, Filter, And Chassis Line Routing The fuel tank is located at the rear of the vehicle between the frame rails. The fuel lines, hoses, and filter are routed along the right hand (passengers) frame rail. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Fuel Tank/Lines/Filler Tube Operation Fuel Supply Line: Description and Operation Fuel Tank/Lines/Filler Tube Operation Hoses The hoses used on fuel injected models are of a special type and only hoses marked EFI/EFM may be used as replacements. Fittings and Clamps There are two ways that the fuel lines are attached to various fuel system components. - The first way is with a rolled edge type clamp (the purpose of the rolled edge is to prevent the clamp from cutting the fuel hoses). Quick Connect Fuel Fitting Assembly - The second type of fitting is called a Quick-Connect fuel fitting. These fittings consist of internal O-rings, a metal locking retainer, and a plastic release collar to disconnect the fitting from the fuel tube. No-Lead Filler Tube All catalyst equipped models have a special filler tube. The filler tube also contains a deflector to prevent the addition of fuel by other than an unleaded fuel nozzle. "Unleaded Fuel Only" Labels are attached at the instrument panel and near the fuel door, to remind the operator. Pressure/Vacuum Filler Cap The loss of liquid fuel or vapor is prevented by using a filler cap which releases under 10.9 to 13.45 kPa (1.58 to 1.95 psi). Only caps with these specifications may be used as replacements to maintain the integrity of the fuel system. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Fuel Tank/Lines/Filler Tube Operation > Page 3548 Fuel Supply Line: Description and Operation Quick-Connect Fitting Operation Disassembly Quick Connect Fuel Fittings Notes: Some fuel lines have quick connect fittings, which are designed to speed up the installation and removal of fuel lines (Fig. 3). Quick connect fittings consist of a metal casing, a black plastic release ring, a metal locking retainer, and internal O-rings. Warning: Fuel system pressure must be released before disconnecting any fuel system component. 1. Disconnect the negative battery cable. 2. Remove the fuel tank gas cap to release fuel tank pressure. 3. Perform the Fuel System Pressure Release Procedure. 4. Remove any loose dirt from quick connect fittings. CAUTION: Wrap shop towels around hoses to catch any gasoline spillage. 5. To remove the fuel tube nipple from a quick connect fitting, pull back on the fitting while pushing in on the plastic ring. To aid in disassembly, an open end wrench may be used to push the plastic ring in. 6. Cover the quick connector to prevent contamination. Assembly 1. Inspect the quick connect fitting to ensure the black plastic release ring is in the OUT position. If the locking retainer is stuck in the RELEASE position, due to mushrooming of the release ring or dirt accumulation, the fitting should be replaced. CAUTION: The fuel tube nipples must be lubricated with clean 30 weight engine oil prior to connecting the quick-connect fitting. 2. Lubricate the male end of the fuel tube with 30 weight engine oil. 3. Insert fuel tube nipple into quick connector fitting. When the fuel tube nipple is inserted into the quick-connect fitting, the shoulder of the nipple is locked in place by the locking retainer and the internal O-rings seal the tube. 4. Pull back on the quick connect fitting to verify the connection is secure. The tube should be locked in place. If the connection is not complete, make sure the black plastic release is not causing the locking retainer to jam in the release position. CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off position. 5. Using a scan tool, activate the ASD relay, to pressurize the fuel system, and check for leaks. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Fuel Tank/Lines/Filler Tube Operation > Page 3549 Retainer Ring Type Fittings Quick Connect Fitting (Chassis Fuel Tubes) Quick Connect Fitting Assembly/Disassembly (Chassis Fuel Tubes) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Fuel Tank/Lines/Filler Tube Operation > Page 3550 Fuel Line Quick Connect Fitting NOTE: Plastic ring type quick connect fittings are not serviced separately. Do not attempt to repair damaged quick connect fittings or tubes. Replace complete fuel tube/quick connect fitting assembly. Quick Connect Fittings REMOVAL 1. Disconnect negative battery cable. 2. Perform fuel pressure release procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Fuel Tank/Lines/Filler Tube Operation > Page 3551 3. Push the fitting toward the component being serviced while pushing the plastic retainer ring into the fitting. 4. With the ring depressed, pull the fitting from the component. An open-end wrench may be used to assist in unlocking the fittings. The retainer should remain on the fitting. NOTE: The retainer must be pressed squarely into the fitting. If the retainer is cocked it will be difficult to disconnect fitting. 5. While fuel lines are disconnected, plug the lines so that dirt and foreign particles do not enter the lines. 6. Inspect the fitting and connector, and replace as needed. INSTALLATION NOTE: Before reassembling the Quick-Connect fittings, clean with a lint free cloth and lubricate the fuel tube nipples with clean engine oil. CAUTION: Never install quick connect fitting if retainer ring is damaged or stuck in the release position. 1. Check that the black plastic ring is in the OUT position. If the release ring is stuck in the release position due to dirt accumulation or mushrooming of the release ring, the fitting should be replaced. 2. Push the fuel tube into the connector until a click is felt. Check the connection by pulling back lightly on the fuel tube (15 to 30 lbs). It should remain inside the connector, locked in place. Single TAB Type Fittings Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Fuel Tank/Lines/Filler Tube Operation > Page 3552 Quick Connect Fitting Assembly/Disassembly (Except Chassis Fuel Tubes) MANUAL REMOVAL 1. Bend the retainer tabs down. 2. While pulling up on the underside of the retainer tab, push the legs of the retainer clip away from each other. 3. Raise the pull tab until the hooks on the legs of the retainer clip clears the fuel tube. 4. Pull fuel tube out of the Quick-Connect fitting. 5. Check the connector body and retainer for damage. Replace if necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Fuel Tank/Lines/Filler Tube Operation > Page 3553 Disconnecting Quick Connect Fittings (Screwdriver) REMOVAL USING SCREWDRIVER 1. Bend the retainer tabs down. 2. Insert a screwdriver between the retainer clips pull tab and the body of the Quick-Connect fitting. 3. Rotate the screwdriver 90 degrees to lift the retainer clip. 4. Raise the pull tab while pushing the legs of the retainer clip away from each other. 5. Raise the retainer clip until the hooks on the legs of the retainer clip clears the fuel tube. 6. Pull fuel tube out of the Quick-Connect fitting. 7. Check the connector body and retainer for damage. Replace if necessary. Quick Connect Fuel Fitting INSTALLATION Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Fuel Tank/Lines/Filler Tube Operation > Page 3554 1. Before installing the fuel tube into Quick-Connect fitting, clean the fuel tube and lubricate the nipple with new engine oil. 2. Push fuel tube into Quick-Connect fitting until the stop on the fuel tube rests against the back of the Quick-Connect fitting. 3. Push the retainer clip into the slot in the Quick-Connect fitting until it locks in place. 4. Bend the retainer clip tabs up into their locking position. CAUTION: The fuel system remains pressurized after engine has been shut off. Release system pressure prior to opening system. WARNING: Gasoline is extremely volatile, when servicing fuel systems always wear eye protection, keep open flame away from fuel system components, and prohibit smoking in service areas. NOTE: Wrap shop towels around fuel hoses to absorb any fuel that spills during fuel tank replacement Two TAB Type Fittings NOTE: Fuel injection quick connect fittings are not serviced separately. Do not attempt to repair damaged quick connect fittings or tubes. Replace complete fuel tube/quick connect fitting assembly. REMOVAL Fuel Line Quick Connect Fitting Fuel Line Quick Connect Fitting 1. Disconnect negative battery cable. 2. Perform fuel pressure release procedure. 3. Squeeze retainer tabs together and pull quick connect fitting off fuel tube nipple. The retainer will remain on fuel tube. INSTALLATION 1. Using a clean lint free cloth, clean fuel tube nipple and retainer. 2. Using a clean motor oil, lightly lube nipple and retainer. CAUTION: Never install quick connect fitting if retainer is damaged or missing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Fuel Tank/Lines/Filler Tube Operation > Page 3555 Fuel Line Quick Connect Fitting 3. Push fitting over fuel tube until retainer seats and a click is heard. When the fitting is properly locked retainer ears will be visible in the windows. 4. Verify connection by pulling on the fuel tube. If fitting locks in place connection is secure. 5. Using the DRB II select the Automatic Shut Down (ASD) Fuel System Test to pressurize fuel system and check for leaks. Refer to Powertrain Management/Computers and Control Systems/Testing and Inspection/Procedures CAUTION: Unless the test is stopped or the ignition switch is turned to the OFF position the fuel pump relay and the ASD relay will remain energized for 7 minutes by the ASD Fuel System Test Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Fittings Fuel Supply Line: Service and Repair Fuel Fittings Quick Connect Fittings 1. Disconnect the negative battery cable. 2. Remove the gas tank cap to release fuel tank pressure. 3. Perform fuel system pressure release procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 4. Clean fitting to prevent contamination of the system when the system is opened. 5. Wrap hoses with shop towels to contain any fuel spray and catch spilled fuel. 6. Push in on the black plastic ring on the end of the fitting and pull the quick connector from the fuel tube. If more force is needed an open end wrench may be used to push the plastic ring into the nipple. 7. Cut as little fuel tube on each side of the fitting as is needed to leave clean, undistorted ends. 8. Discard fitting and hose ends. 9 If it is necessary to replace fuel hose, hose used must be marked EFM/EFI due to higher system pressure. 10. Replace fittings with the correct size and type fittings. 11. Attach the hoses to the fittings using "rolled edge" hose clamps only, other types of hose clamps may cut into the fuel hose and cause to fuel leaks. Torque hose clamps to 1 Nm (10 in-lbs). NOTE: ASD and fuel pump relays remain energized for 7 minutes during the following test, unless the test is stopped or the ignition switch is turned to the OFF position. 12. Using scan tool, place ignition switch in "RUN" position and use Actuate Output Test "Auto Shutdown (ASD) Relay", to activate fuel pump and pressurize system. 13. Check for leaks. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Fittings > Page 3558 Fuel Supply Line: Service and Repair Fuel Hoses and Clamps NOTE: Fuel injected vehicles use specially constructed hoses. When replacing hoses, only use hoses marked EFM/EFI. 1. Inspect all hose connections (clamps and quick connect fittings) for completeness and leaks. Replace cracked, scuffed, or swelled hoses. Replace hoses that rub against other vehicle components or show sign of wear. 2. When installing FUEL hoses: - Ensure that they are routed away from contact with other vehicle components that could rub against them and cause failure. - Avoid contact with clamps or other components that cause abrasions or scuffing. Ensure that rubber hoses are properly routed and avoid heat sources. - Use only original equipment or equivalent hose clamps, which have rolled edges to prevent the clamp from cutting the hose. Other types of clamps may cut into the hoses and cause high pressure fuel leaks. Tighten hose clamps to 1 N-m (10 in lbs) torque. - For replacement SEE QUICK-CONNECT FITTING REPLACEMENT. See: Service and Repair/Quick-Connect Fitting Replacement Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Locations Fuel Filler Hose: Locations Fuel Tank Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Locations > Page 3563 Fuel Tank, Filter, And Chassis Line Routing The fuel tank is located at the rear of the vehicle between the frame rails. The fuel lines, hoses, and filter are routed along the right hand (passengers) frame rail. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Locations > Page 3564 Fuel Filler Hose: Description and Operation Hoses The hoses used on fuel injected models are of a special type and only hoses marked EFI/EFM may be used as replacements. Fittings and Clamps There are two ways that the fuel lines are attached to various fuel system components. - The first way is with a rolled edge type clamp (the purpose of the rolled edge is to prevent the clamp from cutting the fuel hoses). Quick Connect Fuel Fitting Assembly - The second type of fitting is called a Quick-Connect fuel fitting. These fittings consist of internal O-rings, a metal locking retainer, and a plastic release collar to disconnect the fitting from the fuel tube. No-Lead Filler Tube All catalyst equipped models have a special filler tube. The filler tube also contains a deflector to prevent the addition of fuel by other than an unleaded fuel nozzle. "Unleaded Fuel Only" Labels are attached at the instrument panel and near the fuel door, to remind the operator. Pressure/Vacuum Filler Cap The loss of liquid fuel or vapor is prevented by using a filler cap which releases under 10.9 to 13.45 kPa (1.58 to 1.95 psi). Only caps with these specifications may be used as replacements to maintain the integrity of the fuel system. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3569 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3570 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3571 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3572 Fuel Gauge Sender: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3573 Fuel Pump System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Page 3574 Fuel Gauge Sender: Description and Operation Fuel Pump MODULE And Connector TYPICAL The fuel level sensor is a variable resistor, whose resistance changes as the level of fuel in the tank change. As the level float arm moves, the wiper on the sensor moves along the trace, either closer to or further away from, the sensor signal terminal. The further away the sensor pickup is, the higher the resistance across the sensor is. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Page 3575 Fuel Gauge Sender: Testing and Inspection SENDING UNIT TEST NOTE: When a problem occurs with a cluster gauge -- before disassembling the cluster to check the gauge -- check for a defective sending unit, sending unit wiring, or body control module. Sending units and wiring can be checked by grounding the connector leads at the sending unit. With the ignition ON grounding the the sending unit wire will cause the fuel or temperature gauge to read at or above maximum. (For fuel sending units this is the center terminal of the Fuel pump module connector.) The following procedure tests the resistance of the level sensor. It does not test the sensor circuit. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fluid level changes. 1. To test the level sensor connect an ohmmeter between the sensor signal terminal and the ground terminal of the fuel pump module connector. (The middle terminal and the terminal farthest away from the middle terminal.) 2. Move the float lever to the full position and empty position and note the resistance at both points. 3. Replace the sensor if the resistance is not within the specified values. - Sensor Full Position 8 ohms maximum - Sensor Empty Position 96.5 - 108.0 ohms Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Page 3576 Fuel Gauge Sender: Service and Repair Fuel level sensor replacement procedure is included in Fuel Pump Module service. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Mounting Straps: > 140294 > Feb > 94 > Fuel Pump - High Pitched Noise Fuel Tank Mounting Straps: Customer Interest Fuel Pump - High Pitched Noise NO: 14-02-94 GROUP: Fuel System EFFECTIVE DATE: Feb. 11, 1994 SUBJECT: Fuel Pump Noise NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-12-93 DATED JUL. 9, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE PARTS INVOLVED AND THE REPAIR PROCEDURE ARE DIFFERENT. THIS IS A COMPLETE REVISION. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO FRONT WHEEL DRIVE VEHICLES. SYMPTOM/CONDITION: The fuel pump produces a high pitched noise while running that is objectionable to the customer. The fuel pump noise will be most noticeable at idle with all accessories turned off. It is normal to be able to hear the fuel pump running while listening outside of the vehicle or while sitting in the rear of the vehicle. DIAGNOSIS: With all the windows and doors closed, the engine running, and all accessories turned off, listen for the fuel pump while sitting in the drivers seat. If excessive fuel pump noise is heard, perform the repair procedure. PARTS REQUIRED (see illustration) REPAIR PROCEDURE: This bulletin involves installing a revised fuel pump, wiring harness (if applicable), fuel tank isolators and revised fuel tank straps. 1 Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370-3105) starting on Page 14-16, drain and remove the fuel tank. 2. Inspect the vehicle for presence of isolated fuel tank straps (P/N 4682784). Isolated straps are painted black and have a rubber pad between the tank and the strap. The old non-isolated straps are silver in color. If the straps are the new isolated version, verify the fuel pump is P/N 4682761. Replace all parts that are not the revised design. 3. FUEL PUMP REPLACEMENT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Mounting Straps: > 140294 > Feb > 94 > Fuel Pump - High Pitched Noise > Page 3585 A) On 1991-1993 model vehicles, disconnect the fuel pump module wiring harness from the body harness and discard it. B) On 1991-1993 model vehicles, connect the revised fuel pump module wiring harness (P/N 4688376) to the body harness. C) Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370-3105) starting on Page 14-8, remove the fuel pump module. D) Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370- 3105) starting on Page 14-10, install the revised fuel pump module (P/N 4682761). 4. FUEL TANK ISOLATION COMPONENT INSTALLATION A) Remove all tar paper material from the top of the fuel tank and/or the fuel tank stringers of the floor pan. B) Remove the backing paper from the foam insulators (P/N 4682788) and apply to the top of the fuel tank. Begin applying the foam insulators at the front weld flange where the old tar paper was (refer to the illustration). C) Using the procedure outlined in the appropriate Service Manual i.e., 1993 Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370- 3105) starting on Page 14-18, install the fuel tank with the revised straps (P/N 4682784) and the revised bolts (P/N 6501893). Torque the bolts to 40 ft.lbs. (54 N-m). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 14-50-90-98.........1.1 Hrs. FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Mounting Straps: > 140294 > Feb > 94 > Fuel Pump - High Pitched Noise Fuel Tank Mounting Straps: All Technical Service Bulletins Fuel Pump - High Pitched Noise NO: 14-02-94 GROUP: Fuel System EFFECTIVE DATE: Feb. 11, 1994 SUBJECT: Fuel Pump Noise NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-12-93 DATED JUL. 9, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE PARTS INVOLVED AND THE REPAIR PROCEDURE ARE DIFFERENT. THIS IS A COMPLETE REVISION. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO FRONT WHEEL DRIVE VEHICLES. SYMPTOM/CONDITION: The fuel pump produces a high pitched noise while running that is objectionable to the customer. The fuel pump noise will be most noticeable at idle with all accessories turned off. It is normal to be able to hear the fuel pump running while listening outside of the vehicle or while sitting in the rear of the vehicle. DIAGNOSIS: With all the windows and doors closed, the engine running, and all accessories turned off, listen for the fuel pump while sitting in the drivers seat. If excessive fuel pump noise is heard, perform the repair procedure. PARTS REQUIRED (see illustration) REPAIR PROCEDURE: This bulletin involves installing a revised fuel pump, wiring harness (if applicable), fuel tank isolators and revised fuel tank straps. 1 Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370-3105) starting on Page 14-16, drain and remove the fuel tank. 2. Inspect the vehicle for presence of isolated fuel tank straps (P/N 4682784). Isolated straps are painted black and have a rubber pad between the tank and the strap. The old non-isolated straps are silver in color. If the straps are the new isolated version, verify the fuel pump is P/N 4682761. Replace all parts that are not the revised design. 3. FUEL PUMP REPLACEMENT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Mounting Straps: > 140294 > Feb > 94 > Fuel Pump - High Pitched Noise > Page 3591 A) On 1991-1993 model vehicles, disconnect the fuel pump module wiring harness from the body harness and discard it. B) On 1991-1993 model vehicles, connect the revised fuel pump module wiring harness (P/N 4688376) to the body harness. C) Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370-3105) starting on Page 14-8, remove the fuel pump module. D) Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370- 3105) starting on Page 14-10, install the revised fuel pump module (P/N 4682761). 4. FUEL TANK ISOLATION COMPONENT INSTALLATION A) Remove all tar paper material from the top of the fuel tank and/or the fuel tank stringers of the floor pan. B) Remove the backing paper from the foam insulators (P/N 4682788) and apply to the top of the fuel tank. Begin applying the foam insulators at the front weld flange where the old tar paper was (refer to the illustration). C) Using the procedure outlined in the appropriate Service Manual i.e., 1993 Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370- 3105) starting on Page 14-18, install the fuel tank with the revised straps (P/N 4682784) and the revised bolts (P/N 6501893). Torque the bolts to 40 ft.lbs. (54 N-m). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 14-50-90-98.........1.1 Hrs. FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Rollover/Pressure Relief Valve <--> [Fuel Tank Pressure Release Valve] > Component Information > Locations Rollover/Pressure Relief Valve: Locations Fuel Tank Assembly The pressure relief/rollover valve is located on the top of the tank, next to the fuel pump. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Rollover/Pressure Relief Valve <--> [Fuel Tank Pressure Release Valve] > Component Information > Locations > Page 3595 Rollover/Pressure Relief Valve: Service and Repair WARNING: The fuel system is under constant pressure, even when the engine is OFF. Always release fuel pressure before servicing any fuel system component. Fuel Tank Assembly Pressure Relief/Roll Over Valve REMOVAL 1. Release fuel system pressure. 2. Remove fuel tank. 3. Slide the blade of a screwdriver between the rubber mounting grommet and the fuel tank, making sure not to slide the screwdriver between the roll-over valve and grommet. Use a second screwdriver to brace the first and pry the roll-over valve out of the tank. 4. Remove the grommet from the valve, and make sure there is no damage or wear evident on the grommet. If grommet is worn it must be replaced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Rollover/Pressure Relief Valve <--> [Fuel Tank Pressure Release Valve] > Component Information > Locations > Page 3596 Pressure Relief/Rollover Valve INSTALLATION 1. Install the rubber grommet into the fuel tank, and seat it around the curled lip of the tank. 2. Lubricate the grommet with power steering fluid, and push roll-over valve into grommet until properly seated. Twist grommet if necessary to align to correct position. 3. Install fuel tank. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Idle Air Control Motor - Whistling Noise Idle Speed/Throttle Actuator - Electronic: Technical Service Bulletins Idle Air Control Motor Whistling Noise NO.: 14-09-93 Rev.A GROUP: Fuel DATE: Nov. 12, 1993 SUBJECT: Idle Air Control Motor Whistle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NO. 14-09-93 DATED 6-4-93, WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. CHANGES INCLUDE MODELS & DIAGNOSIS REVISION. MODELS: ** 1991 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon (AY) Imperial/New Yorker Fifth Avenue 1991 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country** 1993 (LH) Concorde/Intrepid/Vision 1994 (LH) LHS/New Yorker **NOTE: THIS BULLETIN APPLIES TO 3.3L & 3.8L AC & AY; 3.3L AS BUILT PRIOR TO MDH 1108XX; AND LH MODELS BUILT PRIOR TO MDH 0726XX.** SYMPTOM/CONDITION: Vehicle exhibits a high-pitched whistling noise from the engine compartment at idle. The noise may be more prevalent when the engine is under a load such as air conditioning or headlamps on. No whistling can be heard while cruising. DIAGNOSIS: **Place the gear selector in park, set the parking brake, and start the engine. Let the engine idle for several minutes (3 to 5 minutes). Verify there are no vacuum leaks in the engine compartment. Increase the engine RPM's to around 1200 using the throttle. If the whistle sound goes away, perform the repair procedure below. If the whistle does not go away see Technical Service Bulletin No. 21-01-93 published 1-13-93.** PARTS REQUIRED: 1 4612673 Idle Air Control Motor REPAIR PROCEDURE: This bulletin involves the replacement of the idle air control motor. 1. Using the procedures outlined in the appropriate Service Manual, replace the idle air control motor. 2. Run the engine at idle to verify the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 14-30-23-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations Idle Speed/Throttle Actuator - Electronic: Component Locations Throttle Body View With Idle Air Control Motor Idle Air Control Motor And Throttle Position Sensor Mounted on throttle body. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations > Page 3603 Idle Speed/Throttle Actuator - Electronic: Connector Locations Throttle Body View With Idle Air Control Motor - Mounted on throttle body. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3606 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3607 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3608 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3609 Idle Speed/Throttle Actuator - Electronic: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3610 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3611 Idle Air Control Motor Circuit Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3612 Idle Speed/Throttle Actuator - Electronic: Description and Operation Throttle Body View With Idle Air Control Motor LOCATION Mounted on throttle body. PURPOSE Maintains optimum idle speed under varying engine loads. Prevents deceleration die out. OPERATION Powertrain Control Module (PCM) calculates proper idle speed using information from throttle position, vehicle speed, and coolant temperature sensors and brake, and neutral/safety switches. PCM controls idle speed by actuating motor, varying air flow through bypass in throttle body. Prevents decel die out by increasing air flow when throttle is closed suddenly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3613 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection NOTE: Idle Air Control (IAC) motor operation can be tested using a scan tool. CAUTION: Proper safety precautions must be taken when testing the IAC motor. - Set the parking brake and block the drive wheels - Route all scan tool cables away from the cooling fans, drive belt, pulleys. and exhaust components - Provide proper ventilation while operating the engine - Always return the engine idle speed to normal before disconnecting the exerciser tool. - Follow scan tool manufacturer's instructions for testing the IAC motor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3614 Idle Speed/Throttle Actuator - Electronic: Service and Repair Throttle Body View With Idle Air Control Motor Removal 1. Disconnect the negative battery cable. 2. Disconnect motor wiring connector. 3. Remove motor mounting screws (2-25 mm long, Torx head screws), and remove motor, (make sure the O-ring is removed from throttle body). Idle Air Control (IAC) Motor Installation Installation NOTE: If the pintle measures more than 1 in (25 mm), it must be retracted using scan tool [1]. 1. Install motor using a new O-ring, and torque mounting screws to 20 in-lbs (2 Nm). 2. Connect motor wiring connector. 3. Install air cleaner assembly. 4. Connect negative battery cable. Remarks Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3615 [1] Follow scan tool manufacturer's instructions. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Auto Sutdown Relay In the Power Distribution Center left side of engine compartment. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3619 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3620 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3623 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3624 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3625 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3626 Automatic Shut Down (ASD) Relay: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3627 Automatic Shut Down (ASD) Relay: Description and Operation Relay Locations PURPOSE Relay supplies battery voltage to the ignition coil and fuel injector(s). OPERATION Ignition switch in the START or RUN position, and PCM is receiving reference signals from the distributor pick-up. The Powertrain Control Module (PCM) activates the relay (by supplying a ground). If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM interrupts the relay ground and no voltage is supplied to the ignition coil, or fuel injector(s). NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through the same ground circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay NOTE: Relay terminal numbers can be found on the bottom of the relay: TERMINAL IDENTIFICATION - Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times. - Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the components being operated. - Terminal number 86 is connected to a switched (B+) power source (ignition in ON or RUN). - Terminal number 85 is grounded by the PCM. PROCEDURE 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value (ohms) should be 75 ± 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 Volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. Continuity should now be present between terminals number 87 and 30. Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 Volt power source. - If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring Diagrams for fuel system wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center (Relay Locations) Fuel Pump Relay Socket Fuel pump relay is located in LH side of engine compartment in the power distribution center. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3634 Fuel Pump Relay: Description and Operation Relay Locations PURPOSE Relay supplies battery voltage to the fuel pump and oxygen sensor heater element, when grounded by the Powertrain Control Module (PCM). OPERATION The PCM grounds the relay when the ignition switch is in the START or RUN position and the PCM is receiving reference signals from the distributor pick-up. If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM interrupts the relay ground and no voltage is supplied to the fuel pump and oxygen sensor heater element. NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through the same ground circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3635 Fuel Pump Relay: Testing and Inspection NOTE: The relay terminal numbers can be found on the bottom of the relay: TERMINAL IDENTIFICATION - Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times. ^ Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the component being operated. - Terminal number 86 is connected to a switched (+) power source. - Terminal number 85 is grounded by the PCM. PROCEDURE 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value (ohms) should be 75 ± 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 Volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. Continuity should now be present between terminals number 87 and 30. Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 Volt power source. - If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring Diagrams for fuel system wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Auto Sutdown Relay In the Power Distribution Center left side of engine compartment. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3639 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3640 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3643 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3644 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3645 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3646 Automatic Shut Down (ASD) Relay: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3647 Automatic Shut Down (ASD) Relay: Description and Operation Relay Locations PURPOSE Relay supplies battery voltage to the ignition coil and fuel injector(s). OPERATION Ignition switch in the START or RUN position, and PCM is receiving reference signals from the distributor pick-up. The Powertrain Control Module (PCM) activates the relay (by supplying a ground). If the PCM does not receive a signal from the distributor pick-up, (engine not running), the PCM interrupts the relay ground and no voltage is supplied to the ignition coil, or fuel injector(s). NOTE: The PCM controls the Auto Shutdown (ASD) and fuel pump relays simultaneously, through the same ground circuit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay NOTE: Relay terminal numbers can be found on the bottom of the relay: TERMINAL IDENTIFICATION - Terminal number 30 is connected to battery voltage and can be switched or B + (hot) at all times. - Terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the components being operated. - Terminal number 86 is connected to a switched (B+) power source (ignition in ON or RUN). - Terminal number 85 is grounded by the PCM. PROCEDURE 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value (ohms) should be 75 ± 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 Volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. Continuity should now be present between terminals number 87 and 30. Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 Volt power source. - If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Wiring Diagrams for fuel system wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover/Pressure Relief Valve <--> [Rollover Valve, Fuel Tank] > Component Information > Locations Rollover/Pressure Relief Valve: Locations Fuel Tank Assembly The pressure relief/rollover valve is located on the top of the tank, next to the fuel pump. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover/Pressure Relief Valve <--> [Rollover Valve, Fuel Tank] > Component Information > Locations > Page 3653 Rollover/Pressure Relief Valve: Description and Operation Fuel Tank, Filter, And Chassis Line Routing PURPOSE Prevents fuel system damage, by venting the system in the event of high internal pressure or vacuum. Prevents fuel and vapors from escaping into the atmosphere, (except under extreme conditions, see above). OPERATION Rollover Operation Prevents fuel from escaping, (through the EVAP System), in the event of vehicle rollover, the valve will become inverted. In this position the plunger is forced against the guide plate and raw fuel is prevented from flowing through the valve orifice into the vent tube. Vents excess pressure or vacuum to the atmosphere when calibrated valve setting is exceeded. Pressure Relief Operation One way valve allows fuel and vapors to be vented to the EVAP canister. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover/Pressure Relief Valve <--> [Rollover Valve, Fuel Tank] > Component Information > Locations > Page 3654 Rollover/Pressure Relief Valve: Service and Repair WARNING: The fuel system is under constant pressure, even when the engine is OFF. Always release fuel pressure before servicing any fuel system component. Fuel Tank Assembly Pressure Relief/Roll Over Valve REMOVAL 1. Release fuel system pressure. 2. Remove fuel tank. 3. Slide the blade of a screwdriver between the rubber mounting grommet and the fuel tank, making sure not to slide the screwdriver between the roll-over valve and grommet. Use a second screwdriver to brace the first and pry the roll-over valve out of the tank. 4. Remove the grommet from the valve, and make sure there is no damage or wear evident on the grommet. If grommet is worn it must be replaced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover/Pressure Relief Valve <--> [Rollover Valve, Fuel Tank] > Component Information > Locations > Page 3655 Pressure Relief/Rollover Valve INSTALLATION 1. Install the rubber grommet into the fuel tank, and seat it around the curled lip of the tank. 2. Lubricate the grommet with power steering fluid, and push roll-over valve into grommet until properly seated. Twist grommet if necessary to align to correct position. 3. Install fuel tank. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts Throttle Position Sensor: Customer Interest TPS - Harsh, Erratic, Or Delayed Transmission Shifts NO: 18-13-94 Rev. A GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Harsh, Erratic or Delayed Transmission Shifts THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 (AS) Caravan/Voyager/Town & Country 1994 (ES) Chrysler Voyager (Export Only) 1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX). SYMPTOM/CONDITION: Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold soak) and during warm-up. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or III) with the appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full range of travel, full open then full closed, and watch the voltage readings. The voltage change should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic voltage change or no voltage change during throttle movement in encountered, particularly when moving the throttle from wide open to closed throttle, proceed with the following repair.** PARTS REQUIRED: 1 4759001 Throttle Position Sensor REPAIR PROCEDURE: This bulletin involves replacing the throttle position sensor with a revised part. 1. Following the proper procedure, remove and replace the throttle position sensor using the new sensor, P/N 4759001. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-10-95 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts Throttle Position Sensor: All Technical Service Bulletins TPS - Harsh, Erratic, Or Delayed Transmission Shifts NO: 18-13-94 Rev. A GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Harsh, Erratic or Delayed Transmission Shifts THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 (AS) Caravan/Voyager/Town & Country 1994 (ES) Chrysler Voyager (Export Only) 1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX). SYMPTOM/CONDITION: Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold soak) and during warm-up. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or III) with the appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full range of travel, full open then full closed, and watch the voltage readings. The voltage change should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic voltage change or no voltage change during throttle movement in encountered, particularly when moving the throttle from wide open to closed throttle, proceed with the following repair.** PARTS REQUIRED: 1 4759001 Throttle Position Sensor REPAIR PROCEDURE: This bulletin involves replacing the throttle position sensor with a revised part. 1. Following the proper procedure, remove and replace the throttle position sensor using the new sensor, P/N 4759001. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-10-95 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: All Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3675 39 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3676 43 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3677 45 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3678 47 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3679 51 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3680 55 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3681 57 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3682 59 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3683 63 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3684 67 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3685 69 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3686 71 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3687 173 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3688 177 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3689 179 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3690 181 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3691 187 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3692 191 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3693 193 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3694 195 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3695 201 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3696 205 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3697 207 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3698 209 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3699 256 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously Wheel Speed Sensor: All Technical Service Bulletins ABS - Warning Light ON Continuously NO: 05-22-94 GROUP: Brakes EFFECTIVE DATE: Dec. 2, 1994 SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor Connector MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) SYMPTOM/CONDITION: Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles brake system will perform as a non-ABS equipped vehicle normally would during this condition. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair as necessary. If an ABS wheel speed sensor DTC is discovered: 1. Disconnect the 2 way connector of the suspect wheel speed sensor. 2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body harness connector. There should be resistance/interference felt between the male and female terminals. 3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic Procedures for further diagnostics. 4. If no resistance/interference is felt at one or both terminals, perform the repair procedure. PARTS REQUIRED: 1 4797997 Kit, Terminal Repair Kit Consists Of: 1 4625196 Terminal, Male 1 Connector/Wire Assembly 2 4778570 Tube, Heat Shrink REPAIR PROCEDURE: This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread female terminals. 1. Cut off the suspect body harness connector and discard. 2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and the new connector/wire assembly. 3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and spread the strands of the wire. 4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands together with the strands prepared in step 3 and twist together. 5. Solder the wires together with ROSIN core solder. 6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 7. Repeat steps 3 - 6 for the other wires. 8. Connect the body harness to the wheel speed sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously > Page 3704 9. Test drive the vehicle and verify proper operation of the ABS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-18-97 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 050694 > Apr > 94 > Antilock Brake System - Wheel Speed Sensor Diagnosis Wheel Speed Sensor: All Technical Service Bulletins Antilock Brake System - Wheel Speed Sensor Diagnosis NO: 05-06-94 GROUP: Brakes DATE: Apr. 1, 1994 SUBJECT: Bendix Antilock-4 Wheel Speed Sensor Diagnosis MODELS: 1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1994 (AP) Shadow/Shadow Convertible/Sundance 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH BENDIX ANTILOCK-4 ABS. DISCUSSION: Bendix Antilock-4 ABS wheel speed sensors that have been returned under warranty for inspection have been and are continuing to be tested. An unusually large number of these wheel speed sensors are being found to have no defects. The following steps must be followed when diagnosing Bendix Antilock-4 ABS equipped vehicles: The diagnostic manual MUST be followed without exception. No shortcuts should be used during the diagnostic procedure. All diagnostic work Must begin with test "1A". All diagnostic work MUST end with "VER-1A". Following the above steps will ensure correct diagnosis of Bendix Antilock-4 ABS issues as well as preventing an unnecessary increase in Expense Per Unit Repaired (EPUR) for your dealership. POLICY: Information only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 051793A > Dec > 93 > ABS - Wheel Speed Sensor Applications Wheel Speed Sensor: All Technical Service Bulletins ABS - Wheel Speed Sensor Applications NO.: 05-17-93 Rev. A GROUP: Brakes DATE: Dec. 22, 1993 SUBJECT: Left Front Wheel Speed Sensor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-17-93 DATED NOV. 12, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1991-1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN ANTILOCK BRAKE SYSTEM (ABS). DISCUSSION: On the vehicles listed above, there are two wheel speed sensors specified for the left front wheel, depending upon the model year. The difference between the two parts is the length of the wiring, and they should not be interchanged. P/N 4683057 has longer wiring and must be used only on **1993 and** 1994 model vehicles. If this part is used on prior model year vehicles the wiring may become damaged. P/N 4509213 must be used only on 1991 ** and 1992 ** model vehicles. If this part is used on a ** later ** model vehicle, the wiring is too short and would have to be routed improperly to connect to the vehicle wiring harness. This may cause damage to the wheel speed sensor wiring. This bulletin supersedes any information in the Mopar Parts Catalog or PAIS at this time. A parts catalog bulletin is being developed and the parts catalog will be revised at a later date. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3718 39 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3719 43 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3720 45 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3721 47 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3722 51 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3723 55 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3724 57 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3725 59 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3726 63 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3727 67 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3728 69 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3729 71 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3730 173 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3731 177 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3732 179 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3733 181 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3734 187 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3735 191 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3736 193 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3737 195 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3738 201 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3739 205 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3740 207 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3741 209 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 3742 256 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously > Page 3747 9. Test drive the vehicle and verify proper operation of the ABS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-18-97 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3756 Throttle Position Sensor: Specifications THROTTLE POSITION .................................................................................................................................... INCREASE IN TPS VOLTAGE 10° Closed Throttle* ....................................................................................................................................................... 0 volts 20° ....................................................................................................................................................... ........... 0.38 volts 30° ....................................................................................................................................................... ........... 0.75 volts 45° Half Throttle ........................................................................................................................................................ 1.31 volts 58° ....................................................................................................................................................... ......... 1.80 volts** 75° ....................................................................................................................................................... ........ 2.43 volts*** 90° Wide Open Throttle .................................................................................................................................................. 3.00 volts * At idle position the throttle blade is open 10°. The throttle blade is rotated 80° when the throttle is moved from the idle position to the "wide open" position, . ** The PCM recognizes a TPS voltage rise of 1.80 volts or more over idle position voltage as "Wide Open Throttle" (WOT). *** If the TPS voltage sensed at the PCM rises 2.43 volts or more above idle position voltage, the PCM shuts off fuel injection. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Throttle Body View With Idle Air Control Motor Idle Air Control Motor And Throttle Position Sensor Mounted on throttle body. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 3759 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3762 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3763 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3764 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3765 Throttle Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3766 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3767 Throttle Position Sensor: Electrical Diagrams Throttle Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 3768 Throttle Position Sensor: Description and Operation PURPOSE PCM uses sensor input with other inputs to determine current operating conditions. PCM adjusts air/fuel mixture (injector pulse width) and ignition timing. OPERATION PCM supplies 5 volt sensor reference voltage. Sensor is a variable resistor (potentiometer), whose resistance is dependent on the angle of the throttle blade (or throttle opening). Output voltage ranges from approximately 0.5 Volts, (at idle position), to approximately 4.0 Volts, (at Wide Open Throttle). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 3769 Throttle Position Sensor: Testing and Inspection NOTE: The following procedure tests the TPS only. To perform a complete test of the TPS and its circuitry, SEE Computers and Control Systems/Testing and Inspection/Procedures/Diagnostic Charts/Introduction. PROCEDURE 1. The TPS can be tested with a digital voltmeter. The center terminal of the TPS is the output terminal. 2. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed), and at Wide Open Throttle (WOT). - At idle, TPS output voltage should be approximately 0.5 to 1.0 volt. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. - At wide open throttle, TPS output should be approximately 3.5 volts. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 3770 Throttle Position Sensor: Adjustments PROCEDURE - The Throttle Position Sensor on this vehicle is fixed and adjustment is not required. - If sensor output voltage is outside acceptable range, sensor should be replaced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 3771 Throttle Position Sensor: Service and Repair Throttle Position Sensor (TPS)/Automatic Idle Speed (AIS) Motor Throttle Position Sensor Removed Removal 1. Disconnect the negative battery cable. 2. Disconnect the Throttle Position Sensor (TPS) wiring connector. 3. Remove the mounting screws (2), and remove the TPS from the throttle shaft. Installation 1. Install the new TPS on the throttle shaft and install screws, torqueing them to 17 in-lbs (2 Nm). 2. Connect the TPS wiring connector. 3. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Testing and Inspection Throttle Body: Testing and Inspection Minimum Air Flow Air Metering Fitting WARNING: Apply parking brake and/or block wheels before performing any engine running test with the vehicle on the ground. PRELIMINARY CHECK 1. With vehicle in PARK (A/T) or NEUTRAL (M/T), START the engine, turn all accessories off, and allow engine to run until the cooling fan cycles at least once. 2. Remove intake air hose from throttle body. 3. Cover Idle Air Control by pass passage with finger. - If engine dies, clean throttle body and retest. SEE MAINTENANCE PROCEDURES. - If engine does not die, proceed with Minimum Air Flow Test. TEST PROCEDURE 1. Disconnect the 3/16" idle purge hose from the throttle body nipple and cap the 3/16" nipple. 2. Disconnect PCV valve and attach metered orifice no. C-5004 (or equivalent 0.125 inch orifice) in the intake manifold PCV nipple. 3. START engine and allow to idle for at least one minute. 4. Using scan tool [1], access MINIMUM AIRFLOW IDLE SPEED TEST. - Idle Air Control (IAC) motor should close the bypass passage fully. - Idle spark advance should become fixed. 5. Compare idle speed on tachometer to specifications below. - If idle rpm is within range, Minimum Air Flow is set correctly. - If idle rpm is not within range, clean the throttle body and retest. SEE FUEL AND AIR INDUCTION/MAINTENANCE PROCEDURES/THROTTLE BODY CLEANING. - If throttle body has already been cleaned, and idle is not within specifications, the problem is not caused by the throttle body. 6. Shut engine OFF, remove; metered orifice, timing light and tachometer. 7. Connect PCV hose. Uncap throttle body purge nipple and connect purge hose. Remarks: [1] Follow scan tool manufacturer's instructions for procedures. ODOMETER READING IDLE SPEED Less than 1000 miles 525-875 RPM More than 1000 miles 575-875 RPM Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Cleaning Throttle Body: Service and Repair Throttle Body Cleaning WARNINGS: ^ Clean throttle body in a well ventilated area. ^ Wear proper eye protection. ^ Wear rubber or butyl gloves when using parts cleaner. If cleaner contacts skin, wash thoroughly. ^ Avoid ingesting cleaner. PURPOSE The throttle body is designed to have a gap between the throttle plate and the throttle bore, at closed throttle (idle), for minimum air flow operation. It is common for deposits to form in the throttle body and intake plenum. Deposits on the throttle plate, and throttle bore, which reduce the minimum air flow gap, can cause idle and driveability problems, (stalling at stops, rough or unstable idle), that may or may not set a Diagnostic Trouble Code (DTC). EXAMPLE: If the minimum air flow gap is reduced enough by deposits, and the throttle plate is closed suddenly (deceleration), the Idle Air Control (IAC) motor cannot adjust fast enough to compensate for the sudden lack of air, and the vehicle stalls. INSPECTION Visually inspect the throttle body for cracks, deformation or tampering. Replace throttle body if there are any signs damage. CLEANING PROCEDURE 1. Remove the throttle body. SEE COMPONENT REPLACEMENT AND REPAIR PROCEDURES. CAUTION: Do not use harsh abrasives or tank solvent washing to clean the throttle body. 2. While holding the throttle open, spray the entire throttle body bore and throttle plate with suitable cleaner. 3. Using a soft scuff pad, clean the throttle body bore and throttle blade (front, back and edges). It is critical that the edges of the throttle blade, and the portion of the throttle bore that are close to the throttle blade when it is closed, are free of deposits. 4. Inspect the intake plenum, and clean, if deposits are visible. 5. Install throttle body, and perform throttle body minimum airflow test. SEE DIAGNOSIS, TESTING AND INSPECTION PROCEDURES NOTES: If vehicle is difficult to start after cleaning throttle body, it may be necessary to reset adaptive memory. SEE Powertrain Management/ Computers and Control Systems/Testing and Inspection/Procedures. If minimum air flow idle speed is still not within specifications, after cleaning the throttle body, and the throttle body shows no signs of physical damage, the problem is not caused by the throttle body. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Cleaning > Page 3777 Throttle Body: Service and Repair Throttle Body Replacement Throttle Body Removal And Replacement REMOVAL 1. Disconnect negative cable from battery cable. 2. Remove air inlet to throttle body hose clamp. 3. Remove 2 screws and air inlet resonator. Fig 102 Throttle Cable Attachment To Throttle Body 4. Remove throttle and the speed control (if equipped) cables from lever and bracket (Fig. 102). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Cleaning > Page 3778 Fig 105 Throttle Body Electrical And Vacuum Connections 5. Disconnect electrical connectors from the idle air control motor and throttle position sensor (TPS) (Fig. 105). 6. Disconnect vacuum hoses from throttle body. 7. Remove throttle body to intake manifold attaching nuts. 8. Remove throttle body and gasket. INSTALLATION 1. Reverse procedure for installation. Tighten throttle body mounting nuts to 25 Nm (225 in lb) torque. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Cable <--> [Throttle Cable/Linkage] > Component Information > Adjustments Accelerator Cable: Adjustments No adjustments available for the throttle cable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Cable <--> [Throttle Cable/Linkage] > Component Information > Adjustments > Page 3782 Accelerator Cable: Service and Repair Throttle Cable Replacement CAUTION: When servicing the accelerator pedal, throttle cable or speed control cable, do not damage or kink the core wire inside the cable sheathing. Removal 1. Working from the engine compartment, hold the throttle body throttle lever in the wide open position. remove the throttle cable from the throttle body cam. 2. From inside the vehicle, hold up the pedal and remove the cable retainer and throttle cable from the upper end of the pedal shaft. 3. Remove retainer clip from throttle cable and grommet at dash panel. 4. From the engine compartment. pull the throttle cable out of the dash panel grommet. The grommet should remain in the dash panel. 5. Remove the throttle cable from throttle bracket by carefully compressing both retaining ears simultaneously. Then gently pull the throttle cable from throttle bracket. Installation 1. From the engine compartment push the housing end fitting into the dash panel grommet. 2. Install the cable housing (throttle body end) into the cable mounting bracket on the engine. 3. From inside the vehicle, hold up the pedal and install the throttle cable and cable retainer in the upper end of the pedal shaft. 4. At the dash panel, install the cable retainer clip between the end of the throttle cable fitting and grommet . 5. From the engine compartment, hold the throttle body lever in the wide open position and install the throttle cable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts Throttle Position Sensor: Customer Interest TPS - Harsh, Erratic, Or Delayed Transmission Shifts NO: 18-13-94 Rev. A GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Harsh, Erratic or Delayed Transmission Shifts THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 (AS) Caravan/Voyager/Town & Country 1994 (ES) Chrysler Voyager (Export Only) 1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX). SYMPTOM/CONDITION: Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold soak) and during warm-up. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or III) with the appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full range of travel, full open then full closed, and watch the voltage readings. The voltage change should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic voltage change or no voltage change during throttle movement in encountered, particularly when moving the throttle from wide open to closed throttle, proceed with the following repair.** PARTS REQUIRED: 1 4759001 Throttle Position Sensor REPAIR PROCEDURE: This bulletin involves replacing the throttle position sensor with a revised part. 1. Following the proper procedure, remove and replace the throttle position sensor using the new sensor, P/N 4759001. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-10-95 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 181394A > Sep > 94 > TPS - Harsh, Erratic, Or Delayed Transmission Shifts Throttle Position Sensor: All Technical Service Bulletins TPS - Harsh, Erratic, Or Delayed Transmission Shifts NO: 18-13-94 Rev. A GROUP: Vehicle Performance DATE: Sep. 9, 1994 SUBJECT: Harsh, Erratic or Delayed Transmission Shifts THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-13-94 DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. ENGINE RESTRICTIONS HAVE BEEN ADDED AND THE DIAGNOSTIC PROCEDURE HAS BEEN REVISED. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 (AS) Caravan/Voyager/Town & Country 1994 (ES) Chrysler Voyager (Export Only) 1994 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES **EQUIPPED WITH THE 3.3L, 3.5L AND 3.8L ENGINE** BUILT BEFORE JULY 1, 1994 (MDH 07-01-XX). SYMPTOM/CONDITION: Delayed, harsh or erratic transmission upshifts. Torque converter lock/unlock bumps, unexpected or harsh downshifts. Condition is more apparent when engine is cold (after a 6 hr. or more cold soak) and during warm-up. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII or III) with the appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. With the DRBII or III, MDS (in dynamic data display **or engine state display**), or the Data Recorder installed, operate the throttle lever and read the throttle position sensor voltage. With the throttle fully closed, the voltage should be 1.2 or less. **Slowly move the throttle through its full range of travel, full open then full closed, and watch the voltage readings. The voltage change should be smooth and should reach 3.7 volts or higher at wide open throttle. If any sticking, erratic voltage change or no voltage change during throttle movement in encountered, particularly when moving the throttle from wide open to closed throttle, proceed with the following repair.** PARTS REQUIRED: 1 4759001 Throttle Position Sensor REPAIR PROCEDURE: This bulletin involves replacing the throttle position sensor with a revised part. 1. Following the proper procedure, remove and replace the throttle position sensor using the new sensor, P/N 4759001. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-10-95 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3796 Throttle Position Sensor: Specifications THROTTLE POSITION .................................................................................................................................... INCREASE IN TPS VOLTAGE 10° Closed Throttle* ....................................................................................................................................................... 0 volts 20° ....................................................................................................................................................... ........... 0.38 volts 30° ....................................................................................................................................................... ........... 0.75 volts 45° Half Throttle ........................................................................................................................................................ 1.31 volts 58° ....................................................................................................................................................... ......... 1.80 volts** 75° ....................................................................................................................................................... ........ 2.43 volts*** 90° Wide Open Throttle .................................................................................................................................................. 3.00 volts * At idle position the throttle blade is open 10°. The throttle blade is rotated 80° when the throttle is moved from the idle position to the "wide open" position, . ** The PCM recognizes a TPS voltage rise of 1.80 volts or more over idle position voltage as "Wide Open Throttle" (WOT). *** If the TPS voltage sensed at the PCM rises 2.43 volts or more above idle position voltage, the PCM shuts off fuel injection. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Throttle Body View With Idle Air Control Motor Idle Air Control Motor And Throttle Position Sensor Mounted on throttle body. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 3799 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3802 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3803 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3804 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3805 Throttle Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3806 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3807 Throttle Position Sensor: Electrical Diagrams Throttle Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 3808 Throttle Position Sensor: Description and Operation PURPOSE PCM uses sensor input with other inputs to determine current operating conditions. PCM adjusts air/fuel mixture (injector pulse width) and ignition timing. OPERATION PCM supplies 5 volt sensor reference voltage. Sensor is a variable resistor (potentiometer), whose resistance is dependent on the angle of the throttle blade (or throttle opening). Output voltage ranges from approximately 0.5 Volts, (at idle position), to approximately 4.0 Volts, (at Wide Open Throttle). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 3809 Throttle Position Sensor: Testing and Inspection NOTE: The following procedure tests the TPS only. To perform a complete test of the TPS and its circuitry, SEE Computers and Control Systems/Testing and Inspection/Procedures/Diagnostic Charts/Introduction. PROCEDURE 1. The TPS can be tested with a digital voltmeter. The center terminal of the TPS is the output terminal. 2. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed), and at Wide Open Throttle (WOT). - At idle, TPS output voltage should be approximately 0.5 to 1.0 volt. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. - At wide open throttle, TPS output should be approximately 3.5 volts. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 3810 Throttle Position Sensor: Adjustments PROCEDURE - The Throttle Position Sensor on this vehicle is fixed and adjustment is not required. - If sensor output voltage is outside acceptable range, sensor should be replaced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 3811 Throttle Position Sensor: Service and Repair Throttle Position Sensor (TPS)/Automatic Idle Speed (AIS) Motor Throttle Position Sensor Removed Removal 1. Disconnect the negative battery cable. 2. Disconnect the Throttle Position Sensor (TPS) wiring connector. 3. Remove the mounting screws (2), and remove the TPS from the throttle shaft. Installation 1. Install the new TPS on the throttle shaft and install screws, torqueing them to 17 in-lbs (2 Nm). 2. Connect the TPS wiring connector. 3. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications 3.3L, 3.8L Except Code T Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations 3.3L, 3.8L Except Code T Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations This vehicle is not equipped with timing marks. However spark advance can be monitored using a DRBII or equivalent scan tool. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3827 Camshaft Position Sensor: Mechanical Specifications Camshaft Position sensor screw ..................................................................................................................................................... 14 Nm (125 in lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor Location The Camshaft Position (CMP) sensor is located on the timing gear cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 3830 Camshaft Position Sensor Location Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3833 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3834 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3835 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3836 Camshaft Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3837 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3838 Camshaft Position Sensor: Electrical Diagrams Camshaft Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3839 Camshaft Position Sensor: Description and Operation Camshaft Sensor PURPOSE - Sensor provides PCM with cylinder identification. - PCM uses sensor input to determine fuel injection sequence and ignition timing. OPERATION Sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). - When a notch aligns with the sensor, voltage spikes high (5.0 volts). - As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. - The number of notches determine the amount of pulses. NOTE: If available, an oscilloscope can display the square wave patterns of each timing event. NOTE: The arrows and cylinder call outs on the following image represent which cylinder the flat spot and notches identify, they do not indicate Top Dead Center (TDC) position. Camshaft Sprocket - When the PCM receives two cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder # 1 are next (on driveplate). - When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number # 2 crankshaft timing marks are next. - After 3 camshaft pulses, the PCM knows cylinder # 4 crankshaft timing marks follow. - One camshaft pulse after the three pulses indicates cylinder # 5. - The two camshaft pulses after cylinder 5 signals cylinder # 6. - The PCM can synchronize on cylinders 1 or 4. NOTE: TDC does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. NOTE: The distance between the sensor and camshaft sprocket is critical to system operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE Powertrain Management/Computers and Control Systems/Camshaft Position Sensor/Service and Repair. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3840 Camshaft Position Sensor: Service and Repair Fig. 7 Camshaft Position Sensor REMOVAL 1. Disconnect sensor electrical connector (Fig. 7). 2. Remove engine mount support bracket. 3. Loosen camshaft position sensor retaining bolt enough to allow slot in sensor to slide past the bolt. NOTE: A light tap to top of sensor prior to removal may reduce force needed for removal. 4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on the sensor case, and the O-ring may make removal difficult. INSTALLATION Notes: If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer from the sensor face completely, before attaching new spacer. If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new sensor (Fig. 5). 1. Inspect O-ring for damage, replace if necessary. 2. Ensure the O-ring is positioned in groove of the sensor, and apply a couple drops of clean engine oil to the O-ring prior to installing the sensor (Fig. 7). 3. Install sensor in the chain case cover and push sensor down until contact is made with the camshaft gear. 4. While holding the sensor in this position install and tighten the retaining bolt 14 Nm (125 in-lbs) torque. 5. Connect sensor electrical connector, and position connector away from the accessory belt 6. Install engine mount support bracket. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3845 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position sensor screw ................................................................................................................................................ 11.9 Nm (105 in lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Crank Position Sensor The Crankshaft Position Sensor is mounted on the transaxle bellhousing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 3848 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3851 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3852 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3853 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3854 Crankshaft Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3855 Crankshaft Position Sensor Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3856 Crankshaft Position Sensor: Electrical Diagrams Crankshaft Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3857 Crankshaft Position Sensor: Description and Operation LOCATION Mounted in transmission housing, above distance sensor. PURPOSE Powertrain Control Module (PCM) uses input to determine basic timing. OPERATION Crankshaft Sensor Driveplate Sensor reads a series of slots cut in transmission driveplate. NOTE: The distance between the sensor and torque converter drive plate is critical to system operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE COMPONENT REPLACEMENT AND REPAIR PROCEDURES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3858 Crankshaft Position Sensor: Service and Repair Fig. 5 Crankshaft Position Sensor Removal 1. Disconnect sensor electrical connector (Fig. 5). 2. Remove sensor retaining bolt. 3. Pull sensor straight up, and out of the transaxle housing. Installation Notes: If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer from the sensor face completely, before attaching new spacer. If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new sensor (Fig. 5). 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. 2. While holding the sensor in this position, install and tighten the retaining bolt to 11.9 Nm (105 in-lbs) torque. 3. Connect sensor electrical connector. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Ignition Cable: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 3867 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 3868 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Ignition Cable: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 3874 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 3875 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 3876 Ignition Cable: Specifications Minimum ..................................................................................................................................................... 250 ohms per inch (3,000 ohms per foot) Maximum ............................................................................................................................................... 1,000 ohms per inch (12,000 ohms per foot) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 3877 Ignition Cable: Description and Operation NOTE: Spark Plug cables are sometimes referred to as "secondary ignition wires". Purpose Transfer electrical current from the distributor to individual spark plugs at each cylinder. Resistance type cables are used to suppress Radio Frequency Interference (RFI), from the ignition system. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Ignition Cable: Initial Inspection and Diagnostic Overview INSPECTION Check the high-tension cable connections for good contact at the ignition coil, distributor cap towers and spark plugs. Terminals should be fully seated. The terminals and covers should be in good condition. Terminals should fit tightly to the ignition coil, distributor cap, and spark plugs. The cover (boot) of the cable should fit tight at the coil tower, distributor tower or spark plug insulator. NOTE: Loose cable connections can cause corrosion and increase resistance resulting in shorter cable service life. To maintain proper sealing at terminal connections, do not disconnect cables. This should only be done when testing. Clean high tension cables with a cloth moistened with a nonflammable solvent and wipe dry. Check for brittle or cracked insulation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3880 Ignition Cable: Component Tests and General Diagnostics Secondary Ignition Cable Insulation Test CAUTION: Do not pull spark plug cables from distributor cap of four cylinder engines. The cables must be released from inside the distributor cap. CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during testing. Excessive heat could damage the catalytic converter. Total test time must not exceed ten minutes. CAUTION: To maintain proper sealing at the terminal connections, the connections should not be broken unless testing indicates high resistance, an open circuit or other damage. INSPECTION Check connections at the coil, distributor cap towers and spark plugs. Terminals should be fully seated, and the nipples and spark plug covers should be in good condition. Covers should fit tightly on the coil, distributor cap towers and spark plug insulators. Cable connections that are loose will corrode and increase the resistance and permit water to enter the towers causing ignition malfunction. INSULATION TEST NOTE: When testing secondary cables for punctures and cracks with an oscilloscope follow the equipment manufacturers instructions. If an oscilloscope is not available, secondary cables can be tested as follows: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. 2. With engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. Check the coil cable the same way. 3. Replace ALL cracked, leaking or faulty cables. RESISTANCE TEST Use an ohmmeter to check resistance type cable for open circuits, loose terminals or high resistance as follows: Remove cable from spark plug. Lift distributor cap from distributor with cables intact. Do not remove cables from cap. The cables must be removed from the spark plugs. Connect the ohmmeter between spark plug end terminal and the corresponding electrode inside the cap, make sure ohmmeter probes arc in good contact. Resistance should be within tolerance shown in the cable resistance chart. If resistance is not within tolerance, remove cable at cap tower and check the cable. If resistance is still not within tolerance, replace cable assembly. Test all spark plug cables in same manner. To test coil to distributor cap high tension cable, remove distributor cap with the cable intact. Do not remove cable from the cap. Connect the ohmmeter between center contact in the cap and remove the cable at coil tower and check cable resistance. If resistance is not within tolerance, replace the cable. Also, check for a loose connection at the tower or for a faulty coil. Inspect coil tower for cracks or carbon tracking. Secondary Ignition Cable Resistance Test CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during testing. Excessive heat could damage the catalytic converter. Total test time must not exceed ten minutes. CAUTION: To maintain proper sealing at the terminal connections, the connections should not be broken unless testing indicates high resistance, an open circuit or other damage. NOTE: Use an ohmmeter to check resistance type cable for open circuits, loose terminals or high resistance as follows: SPARK PLUG CABLES 1. Remove cable from spark plug. 2. Lift distributor cap from distributor with cables intact. Do not remove cables from cap. The cables must be removed from the spark plugs. 3. Connect the ohmmeter between spark plug end terminal and the corresponding electrode inside the cap, ensure probes make good contact. Resistance should be within tolerance. 4. If the resistance is not within tolerance, remove cable at cap tower and check the cable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3881 5. If resistance is still not within tolerance, replace cable assembly. 6. Test all spark plug cables in same manner. COIL TO DISTRIBUTOR HIGH TENSION CABLE 1. Remove distributor cap with the cable intact. Do not remove cable from the cap. 2. Remove the cable at coil tower 3. Connect the ohmmeter between center contact in the cap and the coil end of cable. 4. If resistance is not within tolerance, replace the cable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications Ignition Coil: Electrical Specifications Resistance @ 70-80°F (21-27°C) Toyodenso Primary ................................................................................................................................................ ............................................... 0.51-0.61 ohms Secondary ................................................................. ................................................................................................................... 11,500-13,500 ohms Diamond Primary ................................................................................................................................................ ............................................... 0.52-0.63 ohms Secondary ................................................................. ................................................................................................................... 11,600-15,800 ohms Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications > Page 3886 Ignition Coil: Mechanical Specifications Crankshaft Position sensor screw .................................................................................................................................................... 12 Nm (105 in lbs) Camshaft Position sensor screw ...................................................................................................................................................... 12 Nm (105 in lbs) Coolant Sensor .......................................................................................................... .......................................................................... 7 Nm (60 in lbs) Ignition Coil .................................... ................................................................................................................................................ 12 Nm (105 in lbs) Ignition Switch ................................................................................................................... ................................................................. 2 Nm (17 in lbs) Spark Plugs ............................................. ........................................................................................................................................... 28 Nm (20 ft lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Component Locations Ignition Coil: Component Locations Ignition Coil And Coolant Temperature Sensor Location Coil pack mounted on intake manifold, above thermostat housing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Component Locations > Page 3889 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions Ignition Coil: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3892 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3893 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3894 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3895 Ignition Coil: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3896 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3897 Ignition Coil Circuit Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3898 Ignition Coil: Description and Operation Molded Coil LOCATION Mounted on the intake plenum, above thermostat housing. PURPOSE Steps up primary voltage of 12 Volts to a secondary voltage great enough to arc across the spark plug gap, and ignite the air fuel mixture, (25,000-35,000 Volts). OPERATION The PCM uses the Camshaft and Crankshaft Position (CKP) sensor inputs to determine when to charge and fire the coils. The Powertrain Control Module (PCM), Controls Ignition Dwell And Timing Through The Coil Primary Ground. Power is supplied to the positive side of coils by the ASD relay. When the primary windings of a coil are grounded by the PCM, current flow in the windings generates an electromagnetic field. (Low primary resistance of 0.57-0.7 ohms, allows the PCM to fully charge each coil in a very short period). The electromagnetic field is concentrated by the iron core. When the ground is removed, the concentrated field collapses, inducing high voltage in the secondary windings. Secondary Voltage Is Routed To The Spark Plugs Via The Secondary Ignition Cables, (in pairs). Each coil within the pack is wired to fire two spark plugs at the same time, waste spark system. (One negative voltage and the other positive.) - The coil outputs are wired so that when one plug is fired during a compression stroke, the other plug being fired is on an exhaust stroke, (waste spark system). - The next time this coil is fired, the plug that was on the exhaust stroke will be on the compression stroke and the one that was on the compression stroke will be on the exhaust stroke. CONSTRUCTION The coil pack consists of three epoxy filled ignition coils molded together in one pack. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3899 Each coil consists of a primary winding, (2-3 hundred turns of heavy gauge wire), over the secondary windings, (30-40 thousand turns of light gauge wire), wrapped around a soft iron core, embedded in an epoxy compound to protect the coil from vibration damage. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3900 Ignition Coil: Service and Repair Fig 2 Ignition Coil Removal REMOVAL 1. Remove spark plug cables from coil (Fig. 2). - Always twist the spark plug boots to break the seal with the plug and pull straight back on the boot. 2. Remove ignition coil electrical connector. 3. Remove ignition coil mounting screws. 4. Remove ignition coil. INSTALLATION 1. Reverse the above procedure for installation. - Tighten mounting screws to 12 Nm (105 in lb) torque. 2. Transfer spark plug cables to new coil pack. - The coil pack towers and cables are numbered with the cylinder identification. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3905 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3906 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3907 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3908 Ignition Control Module: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3914 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3915 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3916 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3917 Ignition Control Module: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3923 Camshaft Position Sensor: Mechanical Specifications Camshaft Position sensor screw ..................................................................................................................................................... 14 Nm (125 in lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor Location The Camshaft Position (CMP) sensor is located on the timing gear cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 3926 Camshaft Position Sensor Location Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3929 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3930 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3931 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3932 Camshaft Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3933 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3934 Camshaft Position Sensor: Electrical Diagrams Camshaft Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3935 Camshaft Position Sensor: Description and Operation Camshaft Sensor PURPOSE - Sensor provides PCM with cylinder identification. - PCM uses sensor input to determine fuel injection sequence and ignition timing. OPERATION Sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). - When a notch aligns with the sensor, voltage spikes high (5.0 volts). - As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. - The number of notches determine the amount of pulses. NOTE: If available, an oscilloscope can display the square wave patterns of each timing event. NOTE: The arrows and cylinder call outs on the following image represent which cylinder the flat spot and notches identify, they do not indicate Top Dead Center (TDC) position. Camshaft Sprocket - When the PCM receives two cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder # 1 are next (on driveplate). - When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number # 2 crankshaft timing marks are next. - After 3 camshaft pulses, the PCM knows cylinder # 4 crankshaft timing marks follow. - One camshaft pulse after the three pulses indicates cylinder # 5. - The two camshaft pulses after cylinder 5 signals cylinder # 6. - The PCM can synchronize on cylinders 1 or 4. NOTE: TDC does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. NOTE: The distance between the sensor and camshaft sprocket is critical to system operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE Powertrain Management/Computers and Control Systems/Camshaft Position Sensor/Service and Repair. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3936 Camshaft Position Sensor: Service and Repair Fig. 7 Camshaft Position Sensor REMOVAL 1. Disconnect sensor electrical connector (Fig. 7). 2. Remove engine mount support bracket. 3. Loosen camshaft position sensor retaining bolt enough to allow slot in sensor to slide past the bolt. NOTE: A light tap to top of sensor prior to removal may reduce force needed for removal. 4. Pull sensor up out of the chain case cover. Do not pull on the sensor lead. There is an O-ring on the sensor case, and the O-ring may make removal difficult. INSTALLATION Notes: If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer from the sensor face completely, before attaching new spacer. If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new sensor (Fig. 5). 1. Inspect O-ring for damage, replace if necessary. 2. Ensure the O-ring is positioned in groove of the sensor, and apply a couple drops of clean engine oil to the O-ring prior to installing the sensor (Fig. 7). 3. Install sensor in the chain case cover and push sensor down until contact is made with the camshaft gear. 4. While holding the sensor in this position install and tighten the retaining bolt 14 Nm (125 in-lbs) torque. 5. Connect sensor electrical connector, and position connector away from the accessory belt 6. Install engine mount support bracket. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3941 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position sensor screw ................................................................................................................................................ 11.9 Nm (105 in lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations Crank Position Sensor The Crankshaft Position Sensor is mounted on the transaxle bellhousing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 3944 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3947 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3948 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3949 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3950 Crankshaft Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3951 Crankshaft Position Sensor Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3952 Crankshaft Position Sensor: Electrical Diagrams Crankshaft Position Sensor Circuit Complete System Diagrams For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Diagrams/Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3953 Crankshaft Position Sensor: Description and Operation LOCATION Mounted in transmission housing, above distance sensor. PURPOSE Powertrain Control Module (PCM) uses input to determine basic timing. OPERATION Crankshaft Sensor Driveplate Sensor reads a series of slots cut in transmission driveplate. NOTE: The distance between the sensor and torque converter drive plate is critical to system operation. Be sure paper spacer is attached to sensor face when installing sensor. SEE COMPONENT REPLACEMENT AND REPAIR PROCEDURES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3954 Crankshaft Position Sensor: Service and Repair Fig. 5 Crankshaft Position Sensor Removal 1. Disconnect sensor electrical connector (Fig. 5). 2. Remove sensor retaining bolt. 3. Pull sensor straight up, and out of the transaxle housing. Installation Notes: If the sensor is to be reused, a new paper spacer must be used. Be sure to remove the old spacer from the sensor face completely, before attaching new spacer. If the sensor is being replaced, confirm that there is a paper spacer attached to the face of the new sensor (Fig. 5). 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. 2. While holding the sensor in this position, install and tighten the retaining bolt to 11.9 Nm (105 in-lbs) torque. 3. Connect sensor electrical connector. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition - Tamper Resistant Ignition Cylinder Addition NUMBER: 23-44-94D GROUP: Body DATE: Jun. 3, 1994 Models: 1994 Town & Country, Caravan, Voyager - Publication No. 81-370-4105 DISCUSSION: A new method of ignition key cylinder retention is used on the subject vehicles for improved vehicle security. The ignition key cylinder retaining pin has been replaced with a tamper resistant screw and a bracket, refer to the illustration. A Snap-On TTXR20A2 torx-bit or equivalent is required to remove the screw. The 1995 Dakota service manual was completed prior to this information being available to Service Publications. The vehicles listed as 1994 models only, will have this information already in their corresponding 1995 service manual. DESCRIPTION OF CHANGES Add Tamper Resistant Ignition Key Cylinder Info. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 3960 8D - 37 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 3961 8D - 38 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 3962 8D - 39 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 3963 8D - 39A Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Specifications Spark Plug: Specifications Gap Specifications NOTE: Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Spark Plug Gap ................................................................................................................................... ............................... 1.2 to 1.3 mm (0.048 to 0.053 in) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Specifications > Page 3968 Spark Plug: Specifications Tightening Specifications Spark Plug Torque ............................................................................................................................... ....................................................... 28 Nm (20 ft-lbs) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3969 Spark Plug: Description and Operation Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for spark plug diagnosis. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator NOTE: Replace any spark plugs which have cracked broken or chipped insulators. Symptoms: Insulator chipped or broken. Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap. - Severe detonation also can separate the insulator from the center electrode. - Sudden Rise In Tip Temperature. - Severe Operating Conditions. - Improper Gapping Of Plugs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3972 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3973 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Symptoms: Dry, black deposits on the electrodes. Possible Causes: - On one or two plugs, may be caused by sticking valves or defective spark plug cables. - On the entire set, may be caused by a clogged air cleaner. - Poor Ignition Output NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs do not reach a high enough operating temperature during short operating periods to burn fuel completely. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3974 Spark Plug: Testing and Inspection Electrode Gap Bridging Electrode Gap Bridging Symptoms: Gap between the electrodes bridged by deposits. Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the electrodes. NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3975 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator NOTE: Replace any spark plugs which have cracked broken or chipped insulators. Symptoms: Insulator chipped or broken. Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap. - Severe detonation also can separate the insulator from the center electrode. - Sudden Rise In Tip Temperature. - Severe Operating Conditions. - Improper Gapping Of Plugs. Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Symptoms: Dry, black deposits on the electrodes. Possible Causes: - On one or two plugs, may be caused by sticking valves or defective spark plug cables. - On the entire set, may be caused by a clogged air cleaner. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3976 - Poor Ignition Output NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs do not reach a high enough operating temperature during short operating periods to burn fuel completely. Electrode Gap Bridging Electrode Gap Bridging Symptoms: Gap between the electrodes bridged by deposits. Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the electrodes. NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures. Heavy Colored Deposits DESCRIPTION: Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on the side facing the intake valve. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap, and reinstall .............................................................................................................................................................. .................................................................................... Oil or Ash Encrusted Oil Or Ash Encrusted Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3977 Symptoms: Electrodes encrusted with dry oil or ash. Possible Causes: One or more plugs, evaluate the cause of oil entry into the combustion chamber. Premature Electrode Wear - Preignition Damage Preignition Damage Symptoms: Center electrode dissolves first and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Possible Causes: Excessive combustion chamber temperature. - Incorrect spark plug heat range [1]. - Ignition timing is over advanced - Other operating conditions are causing engine overheating. [1] Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Red, Brown, Yellow or White Deposits - Fuel Additives Scavenger Deposits Symptoms: Red, Brown, White or Yellow deposits. Possible Causes: Normal condition caused by certain fuel additives which are designed to change the nature of deposits and decrease spark plug misfire tendencies. NOTE: Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and be cleaned using standard procedures. Shiny Yellow Glaze DESCRIPTION: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3978 Shiny yellow glaze coating on the insulator. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Metal By-products Of Combustion - Avoid sudden acceleration with wide open throttle after long periods of low speed driving. .............................................................................................................................................................. .................................................................................... Spark Plug Inspection PROCEDURE - Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance Schedules. - Spark plugs that have low mileage may be cleaned and reused if not otherwise defective. Refer to the Spark Plug Condition of this section. After cleaning, file the center electrode flat with a small point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The spark plug gap is 0.89 mm (0.035 in). - Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Spark Plug Resistance Test Resistance should be at least 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Wet Oily Deposits Symptoms: Electrodes coated with excessive wet fuel or oil. Possible Causes: In older engines, wet fouling can be caused by worn rings or excessive cylinder wear. - In new or recently overhauled engines, fouling may occur before normal oil control is achieved. Break-in fouled spark plugs can be usually be cleaned and installed. White or Gray - Burned or Blistered Insulator Spark Plug Overheating Symptoms: White or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in per 1000 miles of operation. Possible Causes: Plug(s) with wrong heat range. - Over advanced ignition timing. - Detonation - Cooling system malfunction - Check for lean air-fuel mixture - Check the torque value of the plugs to ensure good plug-engine seat contact Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 3979 Spark Plug: Adjustments Setting Spark Plug Electrode Gap Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground -- center electrode. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Replacement Notes Spark Plug: Service and Repair Replacement Notes TIP: Always keep plugs in the order they were removed. Any plug that looks different from other plugs indicates a problem in that cylinder. NOTE: For further diagnosis by spark plug condition SEE Ignition System/Spark Plug/Testing and Inspection/Procedures Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Replacement Notes > Page 3982 Spark Plug: Service and Repair Removal and Installation CAUTION: Note routing of secondary ignition cables before removing. Failure to route cables properly may result in radio interference, ignition cross fire, or ignition short to ground. NOTE: Keep plugs in order removed. A plug, that looks different from the rest, could be a problem indicator. REMOVAL 1. Spray compressed air around spark plug to prevent foreign material from entering combustion chamber. 2. Remove spark plug wire by grasping boot and turning 1/2 turn while pulling boot back in a steady motion. 3. Remove spark plug using socket with foam insert. INSPECT FOR: - Color of Deposits - Excessive Deposits - Electrode wear - Cracked or Damaged Threads Or Insulator - Worn or Bent Electrodes - Damaged Gasket INSTALLATION 1. Start plug in cylinder head by hand, to prevent cross threading. CAUTION: Do not overtighten plugs, overtightening can distort plugs resulting in a changed gap. 2. Torque spark plugs to 20 ft-lbs (28 Nm). 3. Install secondary ignition cables on spark plugs, (be sure connectors are pushed onto plug completely). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop Shift Solenoid: Customer Interest A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 3994 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop Shift Solenoid: All Technical Service Bulletins A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 4000 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 4001 Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 4002 Transmission Solenoid Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Torque Converter Clutch Solenoid: Component Locations Automatic Transmission Electrical Connections (4 Speed) Switch mounted in transaxle, (automatic only). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 4007 Torque Converter Clutch Solenoid: Connector Locations Electrical Connections, 3 Speed Automatic Automatic Transmission Electrical Connections (4 Speed) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Description and Operation > 3 Speed Transmission Torque Converter Clutch Solenoid: Description and Operation 3 Speed Transmission Transmission Switches (locations) PURPOSE The PCM applies and removes the ground from this solenoid to engage or disengage the lock-up torque converter. OPERATION The lock-up torque converter is only locked up when the transmission is in direct drive mode. If the PCM receives a signal from the throttle position sensor that an increase or decrease in throttle is needed (when the transmission gear selector is in direct drive), the PCM will disengage the part throttle solenoid causing the lock-up torque converter to be disengaged. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Description and Operation > 3 Speed Transmission > Page 4010 Torque Converter Clutch Solenoid: Description and Operation 4 Speed Overdrive Transmission Automatic Transmission Electrical Connections (4 Speed) PURPOSE The PCM applies and removes the ground from this solenoid to engage or disengage the lock-up torque converter. OPERATION The lock-up torque converter is only locked up when the transmission is in direct drive mode. If the PCM receives a signal from the throttle position sensor that an increase or decrease in throttle is needed (when the transmission gear selector is in direct drive), the PCM will disengage the part throttle solenoid causing the lock-up torque converter to be disengaged. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4021 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4022 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4023 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4024 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4025 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4026 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Control Module: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 4031 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 4032 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts Control Module: Customer Interest A/T - Harsh Gear Engagement/Upshifts/Downshifts NO.: 21-36-93 GROUP: Transmission DATE: Dec. 10, 1993 SUBJECT: Improved Transmission Shift Schedule MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH 09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION. SYMPTOM/CONDITION: Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1 kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary Neutral/Drive garage shifts. Park to Reverse noise (grunt). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4686478 Transmission Control Module AR 4467721 Transmission Fluid - ATF Plus (7176) REPAIR PROCEDURE: This repair involves the replacement of the transmission control module with a module that incorporates revised software, changing the transmission fluid, setting the pinion factor, and transaxle quick learn. 1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is currently installed on the vehicle. This is accomplished by choosing the TSB option under Adjustments. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS INSPECTED AT THE RETURN CENTER. 2. Replace the transmission control module with the new module, following the procedures outlined in the appropriate service manual. 3. Change the transmission fluid following the procedure outlined in the service manual. NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER. 4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and then place gear selector in Neutral. 5. Using the procedures listed in the service manual complete the following: a. Quick Learn Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 4037 b. Electronic Pinion Factor Procedure 6. Drive the vehicle at least 10 miles. 7. Change the transmission fluid again following the procedure outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-06-90 2.1 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4043 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4044 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4045 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4046 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4047 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4048 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Control Module: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 4053 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 4054 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts Control Module: All Technical Service Bulletins A/T - Harsh Gear Engagement/Upshifts/Downshifts NO.: 21-36-93 GROUP: Transmission DATE: Dec. 10, 1993 SUBJECT: Improved Transmission Shift Schedule MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH 09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION. SYMPTOM/CONDITION: Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1 kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary Neutral/Drive garage shifts. Park to Reverse noise (grunt). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4686478 Transmission Control Module AR 4467721 Transmission Fluid - ATF Plus (7176) REPAIR PROCEDURE: This repair involves the replacement of the transmission control module with a module that incorporates revised software, changing the transmission fluid, setting the pinion factor, and transaxle quick learn. 1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is currently installed on the vehicle. This is accomplished by choosing the TSB option under Adjustments. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS INSPECTED AT THE RETURN CENTER. 2. Replace the transmission control module with the new module, following the procedures outlined in the appropriate service manual. 3. Change the transmission fluid following the procedure outlined in the service manual. NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER. 4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and then place gear selector in Neutral. 5. Using the procedures listed in the service manual complete the following: a. Quick Learn Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 4059 b. Electronic Pinion Factor Procedure 6. Drive the vehicle at least 10 miles. 7. Change the transmission fluid again following the procedure outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-06-90 2.1 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor Axle Ratio Values Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values NO.: 08-39-93 Rev. A GROUP: Electrical DATE: Sep. 17, 1993 SUBJECT: 41TE Pinion Factor Axle Ratio Values NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** MODELS: **1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue ** DISCUSSION: When installing a replacement TCM (Transmission Control Module), it is necessary to set the pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the speedometer indicates correctly. One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the correct axle ratios for the various applications: YEAR ENGINE SIZE RATIO 1993 3.8L 3.19 3.0L and 3.3L 3.62 1994 3.8L 3.45 3.0L and 3.3L 3.62 POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor Axle Ratio Values Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values NO.: 08-39-93 Rev. A GROUP: Electrical DATE: Sep. 17, 1993 SUBJECT: 41TE Pinion Factor Axle Ratio Values NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** MODELS: **1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue ** DISCUSSION: When installing a replacement TCM (Transmission Control Module), it is necessary to set the pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the speedometer indicates correctly. One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the correct axle ratios for the various applications: YEAR ENGINE SIZE RATIO 1993 3.8L 3.19 3.0L and 3.3L 3.62 1994 3.8L 3.45 3.0L and 3.3L 3.62 POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module Transmission Control Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 4071 Power Control Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 4072 Control Module: Locations Power Distribution Center Power Distribution Center Fuse Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4075 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4076 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4077 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4078 Control Module: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4079 Control Module: Connector Views Part 1 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4080 Part 2 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4081 Part 3 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4082 Part 4 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4083 Part 5 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4084 Part 6 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4085 Part 7 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4086 Part 8 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4087 Part 9 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4088 Part 10 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4089 Part 11 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4090 Transmission Control Schematic Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information Control Module: Description and Operation General Information Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4093 The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transaxle. The TCM receives information from several inputs, and selects the operational mode of the transaxle. Some of the inputs are used only by the TCM, while others are shared with other control modules on the CCD Bus. Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for operating conditions. This is to determine the desired gear range the transaxle must be operated in. The actual shift points within each shift schedule have been predetermined for the best transaxle operation, and are stored in the TCM's ROM memory. Once a TCM is installed during service, the following procedures must be performed: - Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the vehicle - Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes and final drive ratios on 1993 and newer vehicles The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the TCM learning process. The vehicle must still be driven and shifted several times in each gear range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool. NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module display on the DRB III scan tool Emission regulations require the use of two labels after a flash update: - Emission Modification Label - Emission Part Number Modification Label The following provides information on TCM identification and flash programming application: 1989 - 92 Original controllers were non-finned and are non-flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit 1993 - 95 Original controllers were finned with four heat sinks and are flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This TSB also lists the 1990 vehicles that require a wiring modification to pin 49. 1996 Original controllers were finned with seven heat sinks and are flashable - Replacement controllers have fins with seven heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the common DLC Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4094 Control Module: Description and Operation Electronic Transmission Controller Operation LOCATION The EATX control module is located under the hood, in a potted, die cast aluminum housing with a sealed, 60-way connector. ADAPTIVE CONTROLS These controls function by reading the input and output speeds over 140 times a second and responding to each new reading. - This provides the precise friction element control needed to make smooth clutch-to-clutch shifts for all gear changes. As with most automatic transaxles, all shifts involve releasing one element and applying a different element. - In simplified terms, the upshift logic allows the releasing element to slip backwards slightly, to ensure that it does not have excess capacity; the apply element is filled until it begins to make the speed change to the higher gear; its apply pressure is then controlled to maintain the desired rate of speed change until the shift is complete. The key to providing excellent shift quality is precision; EXAMPLE As mentioned, the release element for upshifts is allowed to slip backwards slightly; the amount of that slip is typically less than a total of 20 degrees. LEARNING To achieve that precision, the EATX control module learns the characteristics of the particular transaxle that it is controlling. - It learns the release rate of the releasing element and the apply time of the applying element. - It also learns the rate at which the apply element builds pressure sufficient to begin making the speed change. - This method achieves more precision than would be possible with exacting tolerances. It can also adapt to any changes that occur with age or environment, for example, altitude, temperature, engine output, etc. KICKDOWN SHIFTING For kickdown shifts, the control logic allows the releasing element to slip and then controls the rate at which the input (and engine) accelerate; when the lower gear speed is achieved, the releasing element reapplies to maintain that speed until the apply element is filled. This provides quick response since the engine begins to accelerate immediately and a smooth torque exchange since the release element can control the rate of torque increase. This control can make any power train feel more responsive without increasing harshness. SUMMARY Adaptive controls respond to input speed changes They compensate for changes in engine or friction element torque and provide good, consistent shift quality for the life of the transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information Control Module: Service and Repair General Information Do not interchange Transmission Control Modules with previous-year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: - Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information > Page 4097 Control Module: Service and Repair Replacement NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner. REMOVAL 1. Disconnect the battery negative cable. 2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect the 60 way connector on Transmission Control Module. 3. Remove Transmission Control Module mounting screws and lift module from vehicle. INSTALLATION To install, reverse removal procedures. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Transmission Control Relay Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Transmission Control Relay > Page 4102 Transmission Control System Relay: Locations Transmission (Safety Shut-Down) Relay Transmission Relay Location The Transmission Relay is located in LH side of engine compartment in the Power Distribution Center. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Transmission Control Relay > Page 4103 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4104 Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations > Page 4109 Back Up Lamp Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Override Switch <--> [Overdrive Switch, A/T] > Component Information > Locations Overdrive Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Override Switch <--> [Overdrive Switch, A/T] > Component Information > Locations > Page 4115 Overdrive Off Switch (8 - Way) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4127 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4128 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4129 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4135 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4136 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4141 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4142 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4143 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4149 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4150 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4153 Park Neutral Position Switch / PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4154 Transmission Position Switch/Sensor: Locations 4 Speed A/T Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 4157 Park / Neutral Position Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 4160 Transmission Position Switch/Sensor: Description and Operation Switch, Transmission Range The white Transmission Range Switch (formerly called PRNDL) is used as an input to the Transmission Control Module, on the 4 speed electronic automatic transaxle. Note: The Transmission Range Sensor is a different component from the Transmission Range Switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 4163 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 4164 Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control > Page 4173 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4178 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4179 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4180 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 4186 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4191 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4192 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4193 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4194 Input / Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector Input Speed Sensor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector > Page 4197 Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4198 Transmission Speed Sensor: Description and Operation Three pressure switches incorporated in an assembly with the solenoids identify solenoid application. Two speed sensors read input (torque converter turbine) and output (parking sprag) speeds. Position switch indicates manual shift lever position. Engine speed, throttle position, temperature, etc., are also observed. - Some of these signals are read directly from the engine control sensors; others are read from a multiplex circuit with the powertrain control module. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4199 Transmission Speed Sensor: Testing and Inspection INPUT (TURBINE) SPEED SENSOR INSPECTION 1. Disconnect the input speed sensor connector. 2. Measure the resistance between the input speed sensor side connector terminals 1 and 2. Standard value: 0.3k - 1.2k ohms 3. If the resistance is outside the standard value, replace the input speed sensor. OUTPUT SPEED SENSOR INSPECTION 1. Disconnect the output speed sensor connector. 2. Measure the resistance between the input speed sensor side connector terminals I and 2. Standard value: 0.3k - 1.2k ohms 3. If the resistance is outside the standard value, replace the output speed sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4200 Transmission Speed Sensor: Service and Repair CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Input (Turbine) Speed Sensor INPUT The input speed sensor is located to the left of the manual shift lever. CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Output Speed Sensor OUTPUT The output speed sensor is located to the right of the manual shift lever. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 180197 > Jan > 97 > MIL ON - Erroneously, DTC Hex #2E Set PROM - Programmable Read Only Memory: Customer Interest MIL ON - Erroneously, DTC Hex #2E Set NO: 18-01-97 GROUP: Vehicle Performance DATE: Jan. 17, 1997 SUBJECT: Erroneous MIL Illumination With Hex Code $2e - EGR SYSTEM FAILURE NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-21-95, DATED JUL. 14, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1995 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-96084). THE ENGINE APPLICATIONS HAVE BEEN REVISED. MODELS: 1993 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.0L, 3.3L, OR 3.8L ENGINE APPLICATION. SYMPTOM/CONDITION: 1. Erroneous MIL illumination with DTC Hex $2e - EGR SYSTEM FAILURE - in ambient temperatures below 40° F. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's other than those listed above are present, perform the Repair Procedure. EQUIPMENT REQUIRED: All Symptoms (Flash Programming) 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRBIII ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1124 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes) for all conditions listed. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 180197 > Jan > 97 > MIL ON - Erroneously, DTC Hex #2E Set > Page 4212 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRBIII on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 182295 > Jul > 95 > PCM - Sag or Hesitation on Cold Start Up PROM - Programmable Read Only Memory: Customer Interest PCM - Sag or Hesitation on Cold Start Up NO: 18-22-95 GROUP: Vehicle Performance EFFECTIVE DATE: Jul. 14, 1995 SUBJECT: Sag or Hesitation on Cold Start Up Below 20 Degrees Fahrenheit THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-23-94 DATED DEC. 2, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES OR NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO: 81-699-95054). THE SYMPTOM/CONDITION HAS BEEN REVISED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 - 1995 (AS) Caravan/Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1995 (ES) Chrysler Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO NOV. 1, 1994 (MDH 11-01-XX) AND EQUIPPED WITH THE 3.3L OR THE 3.8L ENGINE. SYMPTOM/CONDITION: Sag or hesitation during operation in ambient temperatures below **20** degrees fahrenheit, high humidity, and usually after the vehicle has been sitting overnight. **The Check Engine Light may be illuminated and Diagnostic Trouble Code (DTC) "EGR SYSTEM FAILURE" may be present.** DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. **If no codes or only DTC "EGR SYSTEM FAILURE" is present and all systems are functioning correctly, proceed with the following repair. ** EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GP1B) 1 CH7015 Engine Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: ** THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER AND TIL CD RELEASE 1085 OR HIGHER MUST BE INSTALLED. ** REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibrations) **which disables EGR diagnostics below 20 degrees fahrenheit.** 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 182295 > Jul > 95 > PCM - Sag or Hesitation on Cold Start Up > Page 4217 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-95 Powertrain Control Module Update 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 180197 > Jan > 97 > MIL ON - Erroneously, DTC Hex #2E Set PROM - Programmable Read Only Memory: All Technical Service Bulletins MIL ON - Erroneously, DTC Hex #2E Set NO: 18-01-97 GROUP: Vehicle Performance DATE: Jan. 17, 1997 SUBJECT: Erroneous MIL Illumination With Hex Code $2e - EGR SYSTEM FAILURE NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-21-95, DATED JUL. 14, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1995 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-96084). THE ENGINE APPLICATIONS HAVE BEEN REVISED. MODELS: 1993 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.0L, 3.3L, OR 3.8L ENGINE APPLICATION. SYMPTOM/CONDITION: 1. Erroneous MIL illumination with DTC Hex $2e - EGR SYSTEM FAILURE - in ambient temperatures below 40° F. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's other than those listed above are present, perform the Repair Procedure. EQUIPMENT REQUIRED: All Symptoms (Flash Programming) 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRBIII ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1124 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes) for all conditions listed. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 180197 > Jan > 97 > MIL ON - Erroneously, DTC Hex #2E Set > Page 4223 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRBIII on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 182295 > Jul > 95 > PCM - Sag or Hesitation on Cold Start Up PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Sag or Hesitation on Cold Start Up NO: 18-22-95 GROUP: Vehicle Performance EFFECTIVE DATE: Jul. 14, 1995 SUBJECT: Sag or Hesitation on Cold Start Up Below 20 Degrees Fahrenheit THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-23-94 DATED DEC. 2, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES OR NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO: 81-699-95054). THE SYMPTOM/CONDITION HAS BEEN REVISED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 - 1995 (AS) Caravan/Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1995 (ES) Chrysler Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO NOV. 1, 1994 (MDH 11-01-XX) AND EQUIPPED WITH THE 3.3L OR THE 3.8L ENGINE. SYMPTOM/CONDITION: Sag or hesitation during operation in ambient temperatures below **20** degrees fahrenheit, high humidity, and usually after the vehicle has been sitting overnight. **The Check Engine Light may be illuminated and Diagnostic Trouble Code (DTC) "EGR SYSTEM FAILURE" may be present.** DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. **If no codes or only DTC "EGR SYSTEM FAILURE" is present and all systems are functioning correctly, proceed with the following repair. ** EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GP1B) 1 CH7015 Engine Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: ** THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER AND TIL CD RELEASE 1085 OR HIGHER MUST BE INSTALLED. ** REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibrations) **which disables EGR diagnostics below 20 degrees fahrenheit.** 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 182295 > Jul > 95 > PCM - Sag or Hesitation on Cold Start Up > Page 4228 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-95 Powertrain Control Module Update 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop Shift Solenoid: Customer Interest A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 4240 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop Shift Solenoid: All Technical Service Bulletins A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 4246 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 4247 Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 4248 Transmission Solenoid Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Torque Converter Clutch Solenoid: Component Locations Automatic Transmission Electrical Connections (4 Speed) Switch mounted in transaxle, (automatic only). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 4253 Torque Converter Clutch Solenoid: Connector Locations Electrical Connections, 3 Speed Automatic Automatic Transmission Electrical Connections (4 Speed) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Description and Operation > 3 Speed Transmission Torque Converter Clutch Solenoid: Description and Operation 3 Speed Transmission Transmission Switches (locations) PURPOSE The PCM applies and removes the ground from this solenoid to engage or disengage the lock-up torque converter. OPERATION The lock-up torque converter is only locked up when the transmission is in direct drive mode. If the PCM receives a signal from the throttle position sensor that an increase or decrease in throttle is needed (when the transmission gear selector is in direct drive), the PCM will disengage the part throttle solenoid causing the lock-up torque converter to be disengaged. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Description and Operation > 3 Speed Transmission > Page 4256 Torque Converter Clutch Solenoid: Description and Operation 4 Speed Overdrive Transmission Automatic Transmission Electrical Connections (4 Speed) PURPOSE The PCM applies and removes the ground from this solenoid to engage or disengage the lock-up torque converter. OPERATION The lock-up torque converter is only locked up when the transmission is in direct drive mode. If the PCM receives a signal from the throttle position sensor that an increase or decrease in throttle is needed (when the transmission gear selector is in direct drive), the PCM will disengage the part throttle solenoid causing the lock-up torque converter to be disengaged. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop Shift Solenoid: Customer Interest A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 4267 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop Shift Solenoid: All Technical Service Bulletins A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 4273 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shift Solenoid: > 140294 > Feb > 94 > Fuel Pump - High Pitched Noise Fuel Tank Mounting Straps: All Technical Service Bulletins Fuel Pump - High Pitched Noise NO: 14-02-94 GROUP: Fuel System EFFECTIVE DATE: Feb. 11, 1994 SUBJECT: Fuel Pump Noise NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-12-93 DATED JUL. 9, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE PARTS INVOLVED AND THE REPAIR PROCEDURE ARE DIFFERENT. THIS IS A COMPLETE REVISION. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO FRONT WHEEL DRIVE VEHICLES. SYMPTOM/CONDITION: The fuel pump produces a high pitched noise while running that is objectionable to the customer. The fuel pump noise will be most noticeable at idle with all accessories turned off. It is normal to be able to hear the fuel pump running while listening outside of the vehicle or while sitting in the rear of the vehicle. DIAGNOSIS: With all the windows and doors closed, the engine running, and all accessories turned off, listen for the fuel pump while sitting in the drivers seat. If excessive fuel pump noise is heard, perform the repair procedure. PARTS REQUIRED (see illustration) REPAIR PROCEDURE: This bulletin involves installing a revised fuel pump, wiring harness (if applicable), fuel tank isolators and revised fuel tank straps. 1 Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370-3105) starting on Page 14-16, drain and remove the fuel tank. 2. Inspect the vehicle for presence of isolated fuel tank straps (P/N 4682784). Isolated straps are painted black and have a rubber pad between the tank and the strap. The old non-isolated straps are silver in color. If the straps are the new isolated version, verify the fuel pump is P/N 4682761. Replace all parts that are not the revised design. 3. FUEL PUMP REPLACEMENT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shift Solenoid: > 140294 > Feb > 94 > Fuel Pump - High Pitched Noise > Page 4279 A) On 1991-1993 model vehicles, disconnect the fuel pump module wiring harness from the body harness and discard it. B) On 1991-1993 model vehicles, connect the revised fuel pump module wiring harness (P/N 4688376) to the body harness. C) Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370-3105) starting on Page 14-8, remove the fuel pump module. D) Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370- 3105) starting on Page 14-10, install the revised fuel pump module (P/N 4682761). 4. FUEL TANK ISOLATION COMPONENT INSTALLATION A) Remove all tar paper material from the top of the fuel tank and/or the fuel tank stringers of the floor pan. B) Remove the backing paper from the foam insulators (P/N 4682788) and apply to the top of the fuel tank. Begin applying the foam insulators at the front weld flange where the old tar paper was (refer to the illustration). C) Using the procedure outlined in the appropriate Service Manual i.e., 1993 Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370- 3105) starting on Page 14-18, install the fuel tank with the revised straps (P/N 4682784) and the revised bolts (P/N 6501893). Torque the bolts to 40 ft.lbs. (54 N-m). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 14-50-90-98.........1.1 Hrs. FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shift Solenoid: > 140294 > Feb > 94 > Fuel Pump - High Pitched Noise > Page 4285 A) On 1991-1993 model vehicles, disconnect the fuel pump module wiring harness from the body harness and discard it. B) On 1991-1993 model vehicles, connect the revised fuel pump module wiring harness (P/N 4688376) to the body harness. C) Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370-3105) starting on Page 14-8, remove the fuel pump module. D) Using the procedure outlined in the appropriate Service Manual, i.e., 1993 Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370- 3105) starting on Page 14-10, install the revised fuel pump module (P/N 4682761). 4. FUEL TANK ISOLATION COMPONENT INSTALLATION A) Remove all tar paper material from the top of the fuel tank and/or the fuel tank stringers of the floor pan. B) Remove the backing paper from the foam insulators (P/N 4682788) and apply to the top of the fuel tank. Begin applying the foam insulators at the front weld flange where the old tar paper was (refer to the illustration). C) Using the procedure outlined in the appropriate Service Manual i.e., 1993 Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370- 3105) starting on Page 14-18, install the fuel tank with the revised straps (P/N 4682784) and the revised bolts (P/N 6501893). Torque the bolts to 40 ft.lbs. (54 N-m). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 14-50-90-98.........1.1 Hrs. FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 4286 Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 4287 Transmission Solenoid Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Torque Converter Clutch Solenoid: Component Locations Automatic Transmission Electrical Connections (4 Speed) Switch mounted in transaxle, (automatic only). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 4292 Torque Converter Clutch Solenoid: Connector Locations Electrical Connections, 3 Speed Automatic Automatic Transmission Electrical Connections (4 Speed) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Description and Operation > 3 Speed Transmission Torque Converter Clutch Solenoid: Description and Operation 3 Speed Transmission Transmission Switches (locations) PURPOSE The PCM applies and removes the ground from this solenoid to engage or disengage the lock-up torque converter. OPERATION The lock-up torque converter is only locked up when the transmission is in direct drive mode. If the PCM receives a signal from the throttle position sensor that an increase or decrease in throttle is needed (when the transmission gear selector is in direct drive), the PCM will disengage the part throttle solenoid causing the lock-up torque converter to be disengaged. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Description and Operation > 3 Speed Transmission > Page 4295 Torque Converter Clutch Solenoid: Description and Operation 4 Speed Overdrive Transmission Automatic Transmission Electrical Connections (4 Speed) PURPOSE The PCM applies and removes the ground from this solenoid to engage or disengage the lock-up torque converter. OPERATION The lock-up torque converter is only locked up when the transmission is in direct drive mode. If the PCM receives a signal from the throttle position sensor that an increase or decrease in throttle is needed (when the transmission gear selector is in direct drive), the PCM will disengage the part throttle solenoid causing the lock-up torque converter to be disengaged. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 213793 > Dec > 93 > A/T Harsh 1-2/2-3 Upshifts & 3-2 Kickdown Accumulator: Customer Interest A/T - Harsh 1-2/2-3 Upshifts & 3-2 Kickdown NO.: 21-37-93 GROUP: Transmission DATE: Dec. 17, 1993 SUBJECT: Transmission Shift Quality Improvement MODELS: 1990 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona 1990 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND 31TH AUTOMATIC TRANSMISSION BUILT PRIOR TO 1994 MODEL MDH 11-01-XX. SYMPTOM/CONDITION: Harsh 2-3 upshifts, 3-2 kickdown, 1-2 upshifts and neutral to reverse shifts. DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with the appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. Check transaxle fluid level and shift linkage for proper function and operation. If the fluid level is correct and the linkage is operating correctly, proceed with the following repair. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves the replacement of the kickdown, accumulator, reverse servo cushion springs and the accumulator piston with revised parts. 1. Following the procedure outlined in the appropriate service manual remove the kickdown spring, accumulator spring, reverse servo cushion spring and the accumulator piston. 2. Install the revised springs and accumulator piston as outlined in the appropriate Service Manual. 3. When performing the Kickdown Band Adjustment, back off 2-1/4 turns from the set torque. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 213793 > Dec > 93 > A/T Harsh 1-2/2-3 Upshifts & 3-2 Kickdown > Page 4304 Labor Operation No. 21-80-03-90 1.2 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 213793 > Dec > 93 > A/T - Harsh 1-2/2-3 Upshifts & 3-2 Kickdown Accumulator: All Technical Service Bulletins A/T - Harsh 1-2/2-3 Upshifts & 3-2 Kickdown NO.: 21-37-93 GROUP: Transmission DATE: Dec. 17, 1993 SUBJECT: Transmission Shift Quality Improvement MODELS: 1990 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon (AG) Daytona 1990 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 3.0L ENGINES AND 31TH AUTOMATIC TRANSMISSION BUILT PRIOR TO 1994 MODEL MDH 11-01-XX. SYMPTOM/CONDITION: Harsh 2-3 upshifts, 3-2 kickdown, 1-2 upshifts and neutral to reverse shifts. DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with the appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. Check transaxle fluid level and shift linkage for proper function and operation. If the fluid level is correct and the linkage is operating correctly, proceed with the following repair. PARTS REQUIRED: REPAIR PROCEDURE: This repair involves the replacement of the kickdown, accumulator, reverse servo cushion springs and the accumulator piston with revised parts. 1. Following the procedure outlined in the appropriate service manual remove the kickdown spring, accumulator spring, reverse servo cushion spring and the accumulator piston. 2. Install the revised springs and accumulator piston as outlined in the appropriate Service Manual. 3. When performing the Kickdown Band Adjustment, back off 2-1/4 turns from the set torque. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 213793 > Dec > 93 > A/T - Harsh 1-2/2-3 Upshifts & 3-2 Kickdown > Page 4310 Labor Operation No. 21-80-03-90 1.2 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature Band Apply Servo: Customer Interest A/T - Slips In Reverse At Low Temperature NO: 21-06-96 GROUP: Transmission DATE: Apr. 26, 1996 SUBJECT: Slips In Reverse At Low Temperature MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX). SYMPTOM/CONDITION: Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these temperature/time conditions is considered normal. DIAGNOSIS: If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If the transaxle also slips going into Drive, further diagnosis is required. PARTS REQUIRED: 1 4659837 Piston, Low/Reverse Servo AR 4318025 Sealant, RTV AR 4467721 Fluid, Mopar Automatic Transmission Type 7176 1 4269649 Filter, Transaxle 1 4269671 Gasket, Transaxle Filter REPAIR PROCEDURE: This bulletin involves installing a revised Low/Reverse servo piston. 1. Raise the vehicle with an appropriate hoist. 2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam. 3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside the oil pan and magnet. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 4319 4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the transaxle oil filter and gasket from the valve body and discard (refer to Figure 1). 5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to Figure 2). 6. Remove the neutral start/back-up lamp switch (refer to Figure 3). 7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes from the transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 4320 8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse servo (refer to Figures 5, 6 and 7). 9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo assembly. 10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs. (4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm). 11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs. (12 Nm). 12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm). 13. Attach the parking rod to the valve body with the parking rod E-clip. 14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the 2 attaching screws to 40 in. lbs. (5 Nm). 15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to 165 in. lbs. (19 Nm). 16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. 17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. 18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the ADD mark on dipstick. 19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 4321 Labor Operation No: 21-80-10-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature Band Apply Servo: All Technical Service Bulletins A/T - Slips In Reverse At Low Temperature NO: 21-06-96 GROUP: Transmission DATE: Apr. 26, 1996 SUBJECT: Slips In Reverse At Low Temperature MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX). SYMPTOM/CONDITION: Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these temperature/time conditions is considered normal. DIAGNOSIS: If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If the transaxle also slips going into Drive, further diagnosis is required. PARTS REQUIRED: 1 4659837 Piston, Low/Reverse Servo AR 4318025 Sealant, RTV AR 4467721 Fluid, Mopar Automatic Transmission Type 7176 1 4269649 Filter, Transaxle 1 4269671 Gasket, Transaxle Filter REPAIR PROCEDURE: This bulletin involves installing a revised Low/Reverse servo piston. 1. Raise the vehicle with an appropriate hoist. 2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam. 3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside the oil pan and magnet. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 4327 4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the transaxle oil filter and gasket from the valve body and discard (refer to Figure 1). 5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to Figure 2). 6. Remove the neutral start/back-up lamp switch (refer to Figure 3). 7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes from the transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 4328 8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse servo (refer to Figures 5, 6 and 7). 9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo assembly. 10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs. (4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm). 11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs. (12 Nm). 12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm). 13. Attach the parking rod to the valve body with the parking rod E-clip. 14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the 2 attaching screws to 40 in. lbs. (5 Nm). 15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to 165 in. lbs. (19 Nm). 16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. 17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. 18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the ADD mark on dipstick. 19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 4329 Labor Operation No: 21-80-10-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch Clutch: Description and Operation Input Clutch The input clutch assembly is located directly behind the oil pump housing, and rides on the reaction shaft support journal. The assembly consists of the following: - Input shaft - Input hub - Clutch retainer - Clutch pistons Overdrive hub Underdrive hub Three input clutches (underdrive clutch, overdrive clutch and reverse clutch). When the torque converter turbine turns, the input shaft, hub and clutch retainer also turn Each of the three clutches in the input clutch assembly supply input power to a particular component in the planetary gear train when they are hydraulically applied. They are connected to the planetary gear-train through the overdrive hub assembly, underdrive hub assembly and the front sun gear assembly. When any of these clutches are applied, they turn or drive a component which is an input to the planetary gear-train. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch > Page 4334 Clutch: Description and Operation Low Reverse Clutch The Low/Reverse (L/R) clutch is used in both low and reverse gears. The L/R clutch is located in the back of the case, directly behind the 2-4 clutch. The L/R clutch actually shares the reaction plate of the 2-4 clutch. It consists of steel plates, clutch discs, belleville return spring, piston and a stamped steel piston retainer which is secured to the back of the case with screws. The L/R clutch surrounds the outside of the front carrier assembly, and locks or grounds the front planetary carrier/rear annulus gear assembly to the case when applied. Similar to the 2-4 clutch, the L/R clutch is a holding element and eliminates the need for bands. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch > Page 4335 Clutch: Description and Operation Overdrive and Reverse Clutch The Overdrive/Reverse (OD/REV) piston is between the input hub and the clutch retainer. This piston is unique in design for the following reasons: - It operates two separate clutches - It is located on the outside of the clutch retainer that houses the two clutches it operates The overdrive clutch is splined to the overdrive hub assembly, and the overdrive hub is splined to the front carrier assembly. When the overdrive clutch is applied hydraulically, the front carrier assembly is an input to the planetary gear-set in third (direct) and fourth (overdrive) gear ranges. The reverse clutch is splined to the front sun gear assembly. When the reverse clutch is applied hydraulically, it drives the front sun gear which is the input to the planetary gear-set in reverse gear range. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch > Page 4336 Clutch: Description and Operation Underdrive Clutch The underdrive piston, piston return spring and spring retainer are inside and to the front of the clutch retainer. These parts control the application of the Underdrive (UD) clutch. The underdrive clutch is named for its use in the three forward underdrive gear ranges: first, second and third. The underdrive clutch is splined to the underdrive hub assembly. The underdrive shaft, which is secured to the underdrive hub, is splined to the rear sun gear. When the underdrive clutch is applied hydraulically, the rear sun gear is the input to the planetary gear-set in first, second and third gears. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch > Page 4337 Clutch: Description and Operation 2-4 Clutch The 2-4 clutch is used in both second and fourth gears, and is located directly behind the input clutch assembly. The clutch consists of the following: - Stamped steel clutch piston retainer - Aluminum piston - Belleville return spring - Clutch plates - Steel separator plates - Reaction Plate The above parts are held in the case with snap rings. The 2-4 clutch surrounds the outside of the front sun gear assembly and when applied hydraulically, locks or grounds the front sun gear assembly to the case. The 2-4 clutch is a holding element. It is a multidisc clutch that provides more room within the transaxle, and eliminates the need for using a band and servo as are used in other transaxle applications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4346 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4347 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4348 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4349 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4350 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4351 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Control Module: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 4356 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 4357 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts Control Module: Customer Interest A/T - Harsh Gear Engagement/Upshifts/Downshifts NO.: 21-36-93 GROUP: Transmission DATE: Dec. 10, 1993 SUBJECT: Improved Transmission Shift Schedule MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH 09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION. SYMPTOM/CONDITION: Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1 kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary Neutral/Drive garage shifts. Park to Reverse noise (grunt). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4686478 Transmission Control Module AR 4467721 Transmission Fluid - ATF Plus (7176) REPAIR PROCEDURE: This repair involves the replacement of the transmission control module with a module that incorporates revised software, changing the transmission fluid, setting the pinion factor, and transaxle quick learn. 1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is currently installed on the vehicle. This is accomplished by choosing the TSB option under Adjustments. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS INSPECTED AT THE RETURN CENTER. 2. Replace the transmission control module with the new module, following the procedures outlined in the appropriate service manual. 3. Change the transmission fluid following the procedure outlined in the service manual. NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER. 4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and then place gear selector in Neutral. 5. Using the procedures listed in the service manual complete the following: a. Quick Learn Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 4362 b. Electronic Pinion Factor Procedure 6. Drive the vehicle at least 10 miles. 7. Change the transmission fluid again following the procedure outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-06-90 2.1 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4368 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4369 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4370 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4371 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4372 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4373 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Control Module: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 4378 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 4379 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts Control Module: All Technical Service Bulletins A/T - Harsh Gear Engagement/Upshifts/Downshifts NO.: 21-36-93 GROUP: Transmission DATE: Dec. 10, 1993 SUBJECT: Improved Transmission Shift Schedule MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH 09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION. SYMPTOM/CONDITION: Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1 kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary Neutral/Drive garage shifts. Park to Reverse noise (grunt). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4686478 Transmission Control Module AR 4467721 Transmission Fluid - ATF Plus (7176) REPAIR PROCEDURE: This repair involves the replacement of the transmission control module with a module that incorporates revised software, changing the transmission fluid, setting the pinion factor, and transaxle quick learn. 1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is currently installed on the vehicle. This is accomplished by choosing the TSB option under Adjustments. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS INSPECTED AT THE RETURN CENTER. 2. Replace the transmission control module with the new module, following the procedures outlined in the appropriate service manual. 3. Change the transmission fluid following the procedure outlined in the service manual. NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER. 4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and then place gear selector in Neutral. 5. Using the procedures listed in the service manual complete the following: a. Quick Learn Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 4384 b. Electronic Pinion Factor Procedure 6. Drive the vehicle at least 10 miles. 7. Change the transmission fluid again following the procedure outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-06-90 2.1 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor Axle Ratio Values Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values NO.: 08-39-93 Rev. A GROUP: Electrical DATE: Sep. 17, 1993 SUBJECT: 41TE Pinion Factor Axle Ratio Values NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** MODELS: **1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue ** DISCUSSION: When installing a replacement TCM (Transmission Control Module), it is necessary to set the pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the speedometer indicates correctly. One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the correct axle ratios for the various applications: YEAR ENGINE SIZE RATIO 1993 3.8L 3.19 3.0L and 3.3L 3.62 1994 3.8L 3.45 3.0L and 3.3L 3.62 POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 110396 > Jun > 96 > Catalytic Converter - Excessive Sulfur Odor Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values NO.: 08-39-93 Rev. A GROUP: Electrical DATE: Sep. 17, 1993 SUBJECT: 41TE Pinion Factor Axle Ratio Values NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** MODELS: **1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue ** DISCUSSION: When installing a replacement TCM (Transmission Control Module), it is necessary to set the pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the speedometer indicates correctly. One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the correct axle ratios for the various applications: YEAR ENGINE SIZE RATIO 1993 3.8L 3.19 3.0L and 3.3L 3.62 1994 3.8L 3.45 3.0L and 3.3L 3.62 POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Transmission Control Module Transmission Control Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 4396 Power Control Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 4397 Control Module: Locations Power Distribution Center Power Distribution Center Fuse Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4400 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4401 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4402 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4403 Control Module: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4404 Control Module: Connector Views Part 1 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4405 Part 2 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4406 Part 3 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4407 Part 4 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4408 Part 5 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4409 Part 6 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4410 Part 7 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4411 Part 8 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4412 Part 9 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4413 Part 10 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4414 Part 11 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4415 Transmission Control Schematic Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information Control Module: Description and Operation General Information Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4418 The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transaxle. The TCM receives information from several inputs, and selects the operational mode of the transaxle. Some of the inputs are used only by the TCM, while others are shared with other control modules on the CCD Bus. Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for operating conditions. This is to determine the desired gear range the transaxle must be operated in. The actual shift points within each shift schedule have been predetermined for the best transaxle operation, and are stored in the TCM's ROM memory. Once a TCM is installed during service, the following procedures must be performed: - Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the vehicle - Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes and final drive ratios on 1993 and newer vehicles The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the TCM learning process. The vehicle must still be driven and shifted several times in each gear range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool. NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module display on the DRB III scan tool Emission regulations require the use of two labels after a flash update: - Emission Modification Label - Emission Part Number Modification Label The following provides information on TCM identification and flash programming application: 1989 - 92 Original controllers were non-finned and are non-flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit 1993 - 95 Original controllers were finned with four heat sinks and are flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This TSB also lists the 1990 vehicles that require a wiring modification to pin 49. 1996 - Original controllers were finned with seven heat sinks and are flashable - Replacement controllers have fins with seven heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the common DLC Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4419 Control Module: Description and Operation Electronic Transmission Controller Operation LOCATION The EATX control module is located under the hood, in a potted, die cast aluminum housing with a sealed, 60-way connector. ADAPTIVE CONTROLS These controls function by reading the input and output speeds over 140 times a second and responding to each new reading. - This provides the precise friction element control needed to make smooth clutch-to-clutch shifts for all gear changes. As with most automatic transaxles, all shifts involve releasing one element and applying a different element. - In simplified terms, the upshift logic allows the releasing element to slip backwards slightly, to ensure that it does not have excess capacity; the apply element is filled until it begins to make the speed change to the higher gear; its apply pressure is then controlled to maintain the desired rate of speed change until the shift is complete. The key to providing excellent shift quality is precision; EXAMPLE As mentioned, the release element for upshifts is allowed to slip backwards slightly; the amount of that slip is typically less than a total of 20 degrees. LEARNING To achieve that precision, the EATX control module learns the characteristics of the particular transaxle that it is controlling. - It learns the release rate of the releasing element and the apply time of the applying element. - It also learns the rate at which the apply element builds pressure sufficient to begin making the speed change. - This method achieves more precision than would be possible with exacting tolerances. It can also adapt to any changes that occur with age or environment, for example, altitude, temperature, engine output, etc. KICKDOWN SHIFTING For kickdown shifts, the control logic allows the releasing element to slip and then controls the rate at which the input (and engine) accelerate; when the lower gear speed is achieved, the releasing element reapplies to maintain that speed until the apply element is filled. This provides quick response since the engine begins to accelerate immediately and a smooth torque exchange since the release element can control the rate of torque increase. This control can make any power train feel more responsive without increasing harshness. SUMMARY Adaptive controls respond to input speed changes They compensate for changes in engine or friction element torque and provide good, consistent shift quality for the life of the transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > General Information Control Module: Service and Repair General Information Do not interchange Transmission Control Modules with previous-year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: - Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > General Information > Page 4422 Control Module: Service and Repair Replacement NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner. REMOVAL 1. Disconnect the battery negative cable. 2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect the 60 way connector on Transmission Control Module. 3. Remove Transmission Control Module mounting screws and lift module from vehicle. INSTALLATION To install, reverse removal procedures. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T > Component Information > Locations Data Link Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T > Component Information > Locations > Page 4426 Data Link Connector, A/T: Diagrams Data Link Connector (8 - Way) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T > Component Information > Locations > Page 4427 Data Link Connector (6 - Way) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T > Component Information > Locations > Page 4428 CCD Data Link Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Technical Service Bulletins > A/T - (41TE) Pinion Factor Axle Ratio Values Differential: Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values NO.: 08-39-93 Rev. A GROUP: Electrical DATE: Sep. 17, 1993 SUBJECT: 41TE Pinion Factor Axle Ratio Values NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** MODELS: **1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue ** DISCUSSION: When installing a replacement TCM (Transmission Control Module), it is necessary to set the pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the speedometer indicates correctly. One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the correct axle ratios for the various applications: YEAR ENGINE SIZE RATIO 1993 3.8L 3.19 3.0L and 3.3L 3.62 1994 3.8L 3.45 3.0L and 3.3L 3.62 POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Technical Service Bulletins > Page 4433 Differential: Description and Operation The 41TE uses a helical-type ring and pinion gear set. The ring gear is bolted to the differential case, and drives the differential case in all gear ranges. The differential case assembly consists of the differential case and within it, two pinion gears, two side gears and a pinion mate shaft retained with a roll pin. The differential case provides input power from the ring gear to the axle shafts through the case, pinion shaft, pinion gears and side gears. The pinion and side gears allow the right and left axles to rotate at different speeds while the vehicle is cornering. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note Differential: Service and Repair Service Note NOTE: The differential is serviced as an assembly. The only parts that are serviceable within the differential are the differential bearing cups and cones. If any other part fails within the differential, you must replace the differential assembly along with the transfer shaft. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 4436 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 4437 Differential: Service and Repair Disassembly The transfer shaft should be removed for differential repair and bearing turning torque checking. Differential Cover Bolts Remove Differential Cover 1. Remove the differential cover and bolts. Differential Retainer Bolts Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 4438 Remove Bearing Retainer 2. Remove the differential bearing retainer and bolts. 3. Using a plastic hammer, remove extension housing/adapter plate on the right side of the transaxle. WARNING: Hold onto differential assembly to prevent it from rolling out of housing. 4. Use Miller Special Tool 5048, 5048-3 Collets, and L-4539-2 Button to remove the differential bearing cone on the extension housing side. Position Button And Collets Onto Differential And Bearing (Ring Gear Side) Position Tool 5048 Over Button And Collets At Differential Bearing (Ring Gear Side) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 4439 Remove Differential Bearing Cone (Ring Gear Side) 5. Use Miller Special Tool 5048, 5048-4 Collets, and L-4539-2 Button to remove the differential bearing cone on the bearing retainer side. 6. Using Miller Special Tool L-4518 remove the differential bearing race from the extension housing. Position Bearing Cup Remover Tool In Retainer Remove Bearing Cup 7. Using Miller Special Tool 6062A remove the differential bearing race from the bearing retainer. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 4440 Differential: Service and Repair Assembly NOTE: Use MOPAR Silicone Rubber Adhesive Sealant, or equivalent, on retainer and extension housing/adapter plate to seal to case. Position Bearing Cone Onto Differential 1. Using Miller Special Tool L-4410, and C-4171, or equivalents, install differential bearing to differential (extension housing side). 2. Using Miller Special Tool 5052 and C-4171, or equivalents, install differential bearing to differential (bearing retainer side). Differential Bearing Retainer 3. Using Miller Special Tool 6061 and C-4171, or equivalents, install differential bearing race to bearing retainer. 4. Using Miller Special Tool L-4520 and C-4171, or equivalents, install differential bearing to extension housing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 4441 Differential: Service and Repair Service Note NOTE: The differential is serviced as an assembly. The only parts that are serviceable within the differential are the differential bearing cups and cones. If any other part fails within the differential, you must replace the differential assembly along with the transfer shaft. Disassembly The transfer shaft should be removed for differential repair and bearing turning torque checking. Differential Cover Bolts Remove Differential Cover 1. Remove the differential cover and bolts. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 4442 Differential Retainer Bolts Remove Bearing Retainer 2. Remove the differential bearing retainer and bolts. 3. Using a plastic hammer, remove extension housing/adapter plate on the right side of the transaxle. WARNING: Hold onto differential assembly to prevent it from rolling out of housing. 4. Use Miller Special Tool 5048, 5048-3 Collets, and L-4539-2 Button to remove the differential bearing cone on the extension housing side. Position Button And Collets Onto Differential And Bearing (Ring Gear Side) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 4443 Position Tool 5048 Over Button And Collets At Differential Bearing (Ring Gear Side) Remove Differential Bearing Cone (Ring Gear Side) 5. Use Miller Special Tool 5048, 5048-4 Collets, and L-4539-2 Button to remove the differential bearing cone on the bearing retainer side. 6. Using Miller Special Tool L-4518 remove the differential bearing race from the extension housing. Position Bearing Cup Remover Tool In Retainer Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 4444 Remove Bearing Cup 7. Using Miller Special Tool 6062A remove the differential bearing race from the bearing retainer. Assembly NOTE: Use MOPAR Silicone Rubber Adhesive Sealant, or equivalent, on retainer and extension housing/adapter plate to seal to case. Position Bearing Cone Onto Differential 1. Using Miller Special Tool L-4410, and C-4171, or equivalents, install differential bearing to differential (extension housing side). 2. Using Miller Special Tool 5052 and C-4171, or equivalents, install differential bearing to differential (bearing retainer side). Differential Bearing Retainer 3. Using Miller Special Tool 6061 and C-4171, or equivalents, install differential bearing race to bearing retainer. 4. Using Miller Special Tool L-4520 and C-4171, or equivalents, install differential bearing to extension housing. Checking Side Gear End Play Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 4445 Checking Side Gear End Play (Extension Housing Side) Checking Side Gear End Play (Bearing Retainer Side) Check side gear end play whenever the differential is removed for service. NOTE: Side gear end play must be BETWEEN 0.001 to 0.013 inch. Differential Bearing Preload Adjustment NOTE: Perform all differential bearing preload measurements with the transfer shaft and gear removed. ADJUSTMENT USING EXISTING SHIM 1. Position the transaxle assembly vertically on the support stand, differential bearing retainer side up. Tool L-4436 And Torque Wrench Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 4446 2. Install Tool L-4436A, or equivalent into the differential and onto the pinion mate shaft. 3. Rotate the differential at least one full revolution to ensure the tapered roller bearings are fully seated. Checking Differential Bearings Turning Torque 4. Using Tool L-4436A, or equivalent and an inch-pound torque wrench, check the turning torque of the differential. The turning torque should be between 5. If the turning torque is within specifications, remove tools. Setup is complete. 6. If turning torque is not within specifications proceed with the following steps. a. Remove differential bearing retainer from the transaxle case. b. Remove the bearing cup from the differential bearing retainer using Tool 6062A, or equivalent. c. Remove the existing shim from under the cup. d. Measure the existing shim. NOTE: If the turning torque was too high when measured, install a 0.05 mm (0.002 inch) thinner shim. If the turning torque is was too low, install a 0.05 mm (0.002 inch) thicker shim. Repeat until 5 to 18 inch pounds turning torque is obtained. Oil Baffle is not required to be installed when making shim selection. e. Install the proper shim under the bearing cup. Make sure the oil baffle is installed properly in the bearing retainer, below the bearing shim and cup. f. Install the differential bearing retainer using Tool 5052 and C-4171, or equivalents. Seal the retainer to the housing with MOPAR Adhesive Sealant and torque bolts to 28 Nm (250 inch lbs.). Checking Differential Bearings Turning Torque 7. Using Tool L-4436A, or equivalent and an inch-pound torque wrench, recheck the turning torque of the differential. The turning torque should be between 5 and 18 inch-pounds. Shim thickness need be determined only if any of the following parts are replaced: Transaxle case - Differential carrier - Differential bearing retainer - Extension housing 8. Attach a dial indicator to the case and zero the dial. Place the tip on the end of Special Tool L-4436-A, or equivalent. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 4447 9. Place a large screwdriver to each side of the ring gear and lift. Check the dial indicator for the amount of end play. CAUTION: Do not damage the transaxle case and/or differential retainer sealing surface. Differential Bearing Shim Chart 10. Using the end play measurement that was determined, add 0.18 mm (0.007 inch). This should give you between 5 and 18 inch pounds of bearing preload. Refer to the Differential Bearing Shim Chart above to determine which shim to use. 11. Remove the differential bearing retainer. Remove the bearing cup. 12. Install the oil baffle. Install the proper shim combination under the bearing cup. 13. Install the differential bearing retainer. Seal the retainer to the housing with MOPAR Silicone Rubber Adhesive Sealant. Torque bolts to 28 Nm (250 inch lbs.). 14. Using Miller Special Tool L-4436-A and an inch-pound torque wrench, check the turning torque of the differential. The turning torque should be between 5 - 18 inch-pounds. NOTE: If turning torque is too high install a 0.05 mm (0.002 inch) thicker shim. If the turning torque is too low, install a 0.05 mm (0.002 inch) thinner shim. Repeat until 5 - 18 inch-pounds of turning torque is obtained. PRELOAD ADJUSTMENT USING GAUGING SHIM (89 - 95 ALL) 1. Remove the bearing cup from the differential bearing retainer using Tool L-4518, and remove the existing shim from under the cup. 2. Install a .50 mm (020 inch) gauging shim into the retainer. Use an arbor press to install the cup. NOTE: Oil Baffle is not required when making shim selection. 3. Install the bearing retainer into the case and torque bolts to 28 Nm (250 in. lbs.). 4. Position the transaxle assembly vertically on the support stand and install Tool C-4995 into side gear. 5. Rotate the differential at least one full revolution to ensure tapered roller bearings are fully seated. 6. Attach a dial indicator to the case and zero the dial indicator. Place the indicator tip on the end of Tool L-4436. 7. Place a large screwdriver to each side of the ring gear and lift. Check the dial indicator for the amount of end play. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Service Note > Page 4448 CAUTION: Do not damage the transaxle case and/or differential cover sealing surface. Differential Bearing Shim Chart 8. When the end play has been determined, refer to the Differential Bearing Shim Chart above for the correct shim combination. 9. remove the differential bearing retainer. Remove the bearing cup and the .50 mm (020 inch) gauging shim. 10 Install the proper shim combination under the bearing cup. make sure the oil baffle is installed properly in the bearing retainer, below the bearing shim and cup. 11. Install the differential bearing retainer. Seal the retainer to the housing with MOPAR RTV sealant. Torque bolts to 28 Nm (250 in. lbs.). 12. Using Tool C-4995 and an inch-pound torque wrench, check the turning torque of the differential. The turning torque should be between 5 and 18 inch pounds. NOTE: If the turning torque is too high, install a .05 mm (.002 inch) thinner shim. If the turning torque is too low, install a .05 mm (.002 inch) thicker shim. Repeat until 5-18 inch pounds turning torque is obtained. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature Fluid - A/T: Customer Interest A/T - Slips In Reverse At Low Temperature NO: 21-06-96 GROUP: Transmission DATE: Apr. 26, 1996 SUBJECT: Slips In Reverse At Low Temperature MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX). SYMPTOM/CONDITION: Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these temperature/time conditions is considered normal. DIAGNOSIS: If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If the transaxle also slips going into Drive, further diagnosis is required. PARTS REQUIRED: 1 4659837 Piston, Low/Reverse Servo AR 4318025 Sealant, RTV AR 4467721 Fluid, Mopar Automatic Transmission Type 7176 1 4269649 Filter, Transaxle 1 4269671 Gasket, Transaxle Filter REPAIR PROCEDURE: This bulletin involves installing a revised Low/Reverse servo piston. 1. Raise the vehicle with an appropriate hoist. 2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam. 3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside the oil pan and magnet. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 4457 4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the transaxle oil filter and gasket from the valve body and discard (refer to Figure 1). 5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to Figure 2). 6. Remove the neutral start/back-up lamp switch (refer to Figure 3). 7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes from the transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 4458 8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse servo (refer to Figures 5, 6 and 7). 9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo assembly. 10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs. (4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm). 11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs. (12 Nm). 12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm). 13. Attach the parking rod to the valve body with the parking rod E-clip. 14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the 2 attaching screws to 40 in. lbs. (5 Nm). 15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to 165 in. lbs. (19 Nm). 16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. 17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. 18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the ADD mark on dipstick. 19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 4459 Labor Operation No: 21-80-10-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts Fluid - A/T: Customer Interest A/T - Harsh Gear Engagement/Upshifts/Downshifts NO.: 21-36-93 GROUP: Transmission DATE: Dec. 10, 1993 SUBJECT: Improved Transmission Shift Schedule MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH 09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION. SYMPTOM/CONDITION: Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1 kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary Neutral/Drive garage shifts. Park to Reverse noise (grunt). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4686478 Transmission Control Module AR 4467721 Transmission Fluid - ATF Plus (7176) REPAIR PROCEDURE: This repair involves the replacement of the transmission control module with a module that incorporates revised software, changing the transmission fluid, setting the pinion factor, and transaxle quick learn. 1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is currently installed on the vehicle. This is accomplished by choosing the TSB option under Adjustments. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS INSPECTED AT THE RETURN CENTER. 2. Replace the transmission control module with the new module, following the procedures outlined in the appropriate service manual. 3. Change the transmission fluid following the procedure outlined in the service manual. NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER. 4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and then place gear selector in Neutral. 5. Using the procedures listed in the service manual complete the following: a. Quick Learn Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 4464 b. Electronic Pinion Factor Procedure 6. Drive the vehicle at least 10 miles. 7. Change the transmission fluid again following the procedure outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-06-90 2.1 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 21-05-97 > Mar > 97 > A/T 41TE/42LE Shudder During EMCC Shift Technical Service Bulletin # 21-05-97 Date: 970314 A/T - 41TE/42LE Shudder During EMCC Shift NO: 21-05-97 GROUP: Transmission DATE: Mar. 14, 1997 SUBJECT: 41TE/42LE Transaxle Shudder During an EMCC (Electronically Modulated Converter Clutch) Shift MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: 1989 TO 1995 MODELS SHOULD HAVE TSB 18-24-95 PERFORMED PRIOR TO PROCEEDING WITH THIS REPAIR PROCEDURE. SYMPTOM/CONDITION: Transaxle shudder during a 3rd gear to 3rd gear partial EMCC (Electronically Modulated Converter Clutch) engagement, 3rd gear partial EMCC to 4th gear partial EMCC engagement, or 4th gear to 4th gear EMCC engagement. Vehicle speed will be above 40 mph to obtain these shift points. This condition can be the result of worn out automatic transaxle fluid, using additives in the transaxle fluid, or from using the wrong type fluid (Dexron II, III, or Mercon) in the transaxle. NOTE: MOPAR ATF+2 TYPE 7176 IS THE ONLY RECOMMENDED FLUID FOR THESE TRANSAXLES. DIAGNOSIS: Bring the vehicle to normal operating temperatures. Drive the vehicle on a smooth road while accelerating through the gears with light throttle application. Pay particular attention during the EMCC shifts that take place between 3rd and 4th gears above 40 mph. If vehicle shudder is noticed during the shifts, perform the Repair Procedure. PARTS REQUIRED: 1 04864505 Filter, 41TE Transaxle 1 04796730 Filter, 42LE Transaxle AR(1) 06032780 0-Ring, Filter AR 04798233 Oil, ATF+2 Type 7176 (Qts) AR(1) 82300234 Sealant, RTV POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-55-01-96 1.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 21-05-97 > Mar > 97 > A/T 41TE/42LE Shudder During EMCC Shift > Page 4470 This repair involves changing the transaxle fluid and filter, driving the vehicle 10 miles and changing the transaxle fluid a second time. 1. Raise the vehicle on a hoist. 2. Clean the transaxle oil pan area and adjoining surfaces. 3. Loosen the transaxle oil pan and drain the fluid into a suitable container. 4. Remove the pan and clean all sealant form the pan and transaxle mating surfaces. Clean the inside of the pan and magnet. 5. Separate the filter and 0-ring from the valve body. Inspect the 0-ring for cuts or improper installation which can lead to delayed garage shifts. 6. Install a new filter p/n 04796730 (42LE) or p/n 04864505 (41TE). Replace the 0-ring p/n 06032780 as necessary. 7. Apply a 1/8 inch bead of Mopar RTV Sealant p/n 82300234 to the mounting flange of the transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to the transaxle and torque the bolts to 19 Nm (165 in. Lbs.). 8. Lower the vehicle and add 4 quarts of Mopar ATF +2 Type 7176 transaxle fluid p/n 04798233 through the transaxle fill tube. 9. Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied, press your foot on the service brake and cycle the transaxle from park to all gear positions ending in neutral or park. 10. Check the transaxle fluid level and add an appropriate amount to bring the level to 3 mm (1/8 in.) below the ADD mark on the dipstick. 11. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range. 12. Drive the vehicle a minimum of 10 miles. 13. Repeat steps 1 through 4. 14. Separate the filter from the valve body to allow additional fluid to drain from the transaxle. Inspect the filter 0-ring for any damage and replace if necessary. 15. After the transaxle has stopped draining, re-install the filter and 0-ring. 16. Complete re-assembly and filling of the transaxle by following steps 7 through 11. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature Fluid - A/T: All Technical Service Bulletins A/T - Slips In Reverse At Low Temperature NO: 21-06-96 GROUP: Transmission DATE: Apr. 26, 1996 SUBJECT: Slips In Reverse At Low Temperature MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX). SYMPTOM/CONDITION: Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these temperature/time conditions is considered normal. DIAGNOSIS: If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If the transaxle also slips going into Drive, further diagnosis is required. PARTS REQUIRED: 1 4659837 Piston, Low/Reverse Servo AR 4318025 Sealant, RTV AR 4467721 Fluid, Mopar Automatic Transmission Type 7176 1 4269649 Filter, Transaxle 1 4269671 Gasket, Transaxle Filter REPAIR PROCEDURE: This bulletin involves installing a revised Low/Reverse servo piston. 1. Raise the vehicle with an appropriate hoist. 2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam. 3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside the oil pan and magnet. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 4475 4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the transaxle oil filter and gasket from the valve body and discard (refer to Figure 1). 5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to Figure 2). 6. Remove the neutral start/back-up lamp switch (refer to Figure 3). 7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes from the transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 4476 8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse servo (refer to Figures 5, 6 and 7). 9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo assembly. 10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs. (4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm). 11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs. (12 Nm). 12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm). 13. Attach the parking rod to the valve body with the parking rod E-clip. 14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the 2 attaching screws to 40 in. lbs. (5 Nm). 15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to 165 in. lbs. (19 Nm). 16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. 17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. 18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the ADD mark on dipstick. 19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 4477 Labor Operation No: 21-80-10-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 213693 > Dec > 93 > A/T Harsh Gear Engagement/Upshifts/Downshifts Fluid - A/T: All Technical Service Bulletins A/T - Harsh Gear Engagement/Upshifts/Downshifts NO.: 21-36-93 GROUP: Transmission DATE: Dec. 10, 1993 SUBJECT: Improved Transmission Shift Schedule MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH 09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION. SYMPTOM/CONDITION: Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1 kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary Neutral/Drive garage shifts. Park to Reverse noise (grunt). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4686478 Transmission Control Module AR 4467721 Transmission Fluid - ATF Plus (7176) REPAIR PROCEDURE: This repair involves the replacement of the transmission control module with a module that incorporates revised software, changing the transmission fluid, setting the pinion factor, and transaxle quick learn. 1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is currently installed on the vehicle. This is accomplished by choosing the TSB option under Adjustments. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS INSPECTED AT THE RETURN CENTER. 2. Replace the transmission control module with the new module, following the procedures outlined in the appropriate service manual. 3. Change the transmission fluid following the procedure outlined in the service manual. NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER. 4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and then place gear selector in Neutral. 5. Using the procedures listed in the service manual complete the following: a. Quick Learn Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 213693 > Dec > 93 > A/T Harsh Gear Engagement/Upshifts/Downshifts > Page 4482 b. Electronic Pinion Factor Procedure 6. Drive the vehicle at least 10 miles. 7. Change the transmission fluid again following the procedure outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-06-90 2.1 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 21-05-97 > Mar > 97 > A/T 41TE/42LE Shudder During EMCC Shift Technical Service Bulletin # 21-05-97 Date: 970314 A/T - 41TE/42LE Shudder During EMCC Shift NO: 21-05-97 GROUP: Transmission DATE: Mar. 14, 1997 SUBJECT: 41TE/42LE Transaxle Shudder During an EMCC (Electronically Modulated Converter Clutch) Shift MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: 1989 TO 1995 MODELS SHOULD HAVE TSB 18-24-95 PERFORMED PRIOR TO PROCEEDING WITH THIS REPAIR PROCEDURE. SYMPTOM/CONDITION: Transaxle shudder during a 3rd gear to 3rd gear partial EMCC (Electronically Modulated Converter Clutch) engagement, 3rd gear partial EMCC to 4th gear partial EMCC engagement, or 4th gear to 4th gear EMCC engagement. Vehicle speed will be above 40 mph to obtain these shift points. This condition can be the result of worn out automatic transaxle fluid, using additives in the transaxle fluid, or from using the wrong type fluid (Dexron II, III, or Mercon) in the transaxle. NOTE: MOPAR ATF+2 TYPE 7176 IS THE ONLY RECOMMENDED FLUID FOR THESE TRANSAXLES. DIAGNOSIS: Bring the vehicle to normal operating temperatures. Drive the vehicle on a smooth road while accelerating through the gears with light throttle application. Pay particular attention during the EMCC shifts that take place between 3rd and 4th gears above 40 mph. If vehicle shudder is noticed during the shifts, perform the Repair Procedure. PARTS REQUIRED: 1 04864505 Filter, 41TE Transaxle 1 04796730 Filter, 42LE Transaxle AR(1) 06032780 0-Ring, Filter AR 04798233 Oil, ATF+2 Type 7176 (Qts) AR(1) 82300234 Sealant, RTV POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-55-01-96 1.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 21-05-97 > Mar > 97 > A/T 41TE/42LE Shudder During EMCC Shift > Page 4488 This repair involves changing the transaxle fluid and filter, driving the vehicle 10 miles and changing the transaxle fluid a second time. 1. Raise the vehicle on a hoist. 2. Clean the transaxle oil pan area and adjoining surfaces. 3. Loosen the transaxle oil pan and drain the fluid into a suitable container. 4. Remove the pan and clean all sealant form the pan and transaxle mating surfaces. Clean the inside of the pan and magnet. 5. Separate the filter and 0-ring from the valve body. Inspect the 0-ring for cuts or improper installation which can lead to delayed garage shifts. 6. Install a new filter p/n 04796730 (42LE) or p/n 04864505 (41TE). Replace the 0-ring p/n 06032780 as necessary. 7. Apply a 1/8 inch bead of Mopar RTV Sealant p/n 82300234 to the mounting flange of the transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to the transaxle and torque the bolts to 19 Nm (165 in. Lbs.). 8. Lower the vehicle and add 4 quarts of Mopar ATF +2 Type 7176 transaxle fluid p/n 04798233 through the transaxle fill tube. 9. Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied, press your foot on the service brake and cycle the transaxle from park to all gear positions ending in neutral or park. 10. Check the transaxle fluid level and add an appropriate amount to bring the level to 3 mm (1/8 in.) below the ADD mark on the dipstick. 11. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range. 12. Drive the vehicle a minimum of 10 miles. 13. Repeat steps 1 through 4. 14. Separate the filter from the valve body to allow additional fluid to drain from the transaxle. Inspect the filter 0-ring for any damage and replace if necessary. 15. After the transaxle has stopped draining, re-install the filter and 0-ring. 16. Complete re-assembly and filling of the transaxle by following steps 7 through 11. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transaxle/Transmission - Automatic See TSB 21-010-06 4/14/2006 CAPACITY, Initial Refill*: All with transverse engine............................................................................ ......................................................................................3.8 Liters 4.0 Quarts All with longitudinal engine................................................................................................................... ............................................4.2 Liters 4.5 Quarts *With the engine at operating temperature, shift transmission through all gears. Check fluid level in PARK and add fluid as needed 1993 Grand Caravan adding or replace, Mopar ATF Plus 4 type 9602. Initial Refill Capacity Automatic.............................................................................................................................................. ..........................................................................AP‡ CAPACITY, Initial Refill*: All with transverse en gine....................................................................................................................................................... ...........3.8 Liters 4.0 Quarts All with longitudinal engine................................................................................................................... ............................................4.2 Liters 4.5 Quarts *With the engine at operating temperature, shift transmission through all gears. Check fluid level in PARK and add fluid as needed ‡May use AF or MA only when AP is not available only for "Topping off" Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4491 Fluid - A/T: Fluid Type Specifications See TSB 21-010-06 4/14/2006 ATF Plus 4 Type 9602 Oil Type ................................................................................................................................................. Mopar (R) ATF Plus 4 Type 9602, Or Equivalent. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check Fluid - A/T: Service and Repair Fluid Level & Condition Check Fluid Level The transmission and differential sump have a common oil sump with a opening between the two. The torque converter fills in both the "P" Park and "N" Neutral positions. Place the selector lever in "P" Park to check fluid level. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. This will assure complete oil level stabilization between differential and transmission. The fluid should be at normal operating temperature (approximately 82 C. or 180 F). The fluid level is correct if it is in the "HOT" region (cross-hatched area) on the oil level indicator. Fluid Condition Along with fluid level, it is important to check the condition of the fluid. - When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transaxle overhaul is needed. Be sure to examine the fluid on the dipstick closely. - If there is any doubt about its condition, drain out a sample for a double check. Note: After the fluid has been checked, seat the dipstick fully to seal out water and dirt. Low Fluid Level Symptoms Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. in any hydraulic system, air bubbles will make the fluid spongy, therefore pressures will be low and build up slowly. Improper Filling Level Symptoms Improper filling can also raise the fluid level too high. - When the transaxle has too much fluid, the gears churn up foam and cause the same conditions which occur with a low fluid level. In either case the air bubbles can cause over heating, fluid oxidation, and varnishing, which can interfere with normal valve, clutch and accumulator operation. Foaming can also result in fluid escaping from the transaxle vent, where it may be mistaken for a leak. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check > Page 4494 Fluid - A/T: Service and Repair Fluid and Filter Change Fluid and Filter Change When the factory fill fluid is changed, only fluids labeled Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 should be used. A filter change should be made at the time of oil change. Also the magnet (on the inside of the oil pan) should be cleaned with a clean dry cloth. If the transaxle is disassembled for any reason, the fluid and filter should be changed. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check > Page 4495 Fluid - A/T: Service and Repair Fluid Drain and Refill Procedure 1. Raise vehicle on a hoist. 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. 4. Clean the oil pan and magnet. Reinstall pan using Mopar RTV Sealant. Tighten oil pan bolts to 19 Nm (165 in-lbs). 5. Pour four quarts of Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 through the fill tube. 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. Add sufficient fluid to bring level to 1/8 inch below the ADD mark on the dipstick. CAUTION: Do not over fill transaxle. Do not add oil if level is between: Lower holes for warm oil (100F). Upper holes for hot oil (180F). 8. Recheck fluid level after transaxle is at normal operating temperature. The level should be in the HOT region. 9. To prevent dirt from entering transaxle, make certain that dipstick is seated into the dipstick fill tube. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature Fluid Filter - A/T: Customer Interest A/T - Slips In Reverse At Low Temperature NO: 21-06-96 GROUP: Transmission DATE: Apr. 26, 1996 SUBJECT: Slips In Reverse At Low Temperature MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX). SYMPTOM/CONDITION: Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these temperature/time conditions is considered normal. DIAGNOSIS: If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If the transaxle also slips going into Drive, further diagnosis is required. PARTS REQUIRED: 1 4659837 Piston, Low/Reverse Servo AR 4318025 Sealant, RTV AR 4467721 Fluid, Mopar Automatic Transmission Type 7176 1 4269649 Filter, Transaxle 1 4269671 Gasket, Transaxle Filter REPAIR PROCEDURE: This bulletin involves installing a revised Low/Reverse servo piston. 1. Raise the vehicle with an appropriate hoist. 2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam. 3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside the oil pan and magnet. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 4504 4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the transaxle oil filter and gasket from the valve body and discard (refer to Figure 1). 5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to Figure 2). 6. Remove the neutral start/back-up lamp switch (refer to Figure 3). 7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes from the transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 4505 8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse servo (refer to Figures 5, 6 and 7). 9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo assembly. 10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs. (4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm). 11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs. (12 Nm). 12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm). 13. Attach the parking rod to the valve body with the parking rod E-clip. 14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the 2 attaching screws to 40 in. lbs. (5 Nm). 15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to 165 in. lbs. (19 Nm). 16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. 17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. 18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the ADD mark on dipstick. 19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 4506 Labor Operation No: 21-80-10-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-05-97 > Mar > 97 > A/T - 41TE/42LE Shudder During EMCC Shift Technical Service Bulletin # 21-05-97 Date: 970314 A/T - 41TE/42LE Shudder During EMCC Shift NO: 21-05-97 GROUP: Transmission DATE: Mar. 14, 1997 SUBJECT: 41TE/42LE Transaxle Shudder During an EMCC (Electronically Modulated Converter Clutch) Shift MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: 1989 TO 1995 MODELS SHOULD HAVE TSB 18-24-95 PERFORMED PRIOR TO PROCEEDING WITH THIS REPAIR PROCEDURE. SYMPTOM/CONDITION: Transaxle shudder during a 3rd gear to 3rd gear partial EMCC (Electronically Modulated Converter Clutch) engagement, 3rd gear partial EMCC to 4th gear partial EMCC engagement, or 4th gear to 4th gear EMCC engagement. Vehicle speed will be above 40 mph to obtain these shift points. This condition can be the result of worn out automatic transaxle fluid, using additives in the transaxle fluid, or from using the wrong type fluid (Dexron II, III, or Mercon) in the transaxle. NOTE: MOPAR ATF+2 TYPE 7176 IS THE ONLY RECOMMENDED FLUID FOR THESE TRANSAXLES. DIAGNOSIS: Bring the vehicle to normal operating temperatures. Drive the vehicle on a smooth road while accelerating through the gears with light throttle application. Pay particular attention during the EMCC shifts that take place between 3rd and 4th gears above 40 mph. If vehicle shudder is noticed during the shifts, perform the Repair Procedure. PARTS REQUIRED: 1 04864505 Filter, 41TE Transaxle 1 04796730 Filter, 42LE Transaxle AR(1) 06032780 0-Ring, Filter AR 04798233 Oil, ATF+2 Type 7176 (Qts) AR(1) 82300234 Sealant, RTV POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-55-01-96 1.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-05-97 > Mar > 97 > A/T - 41TE/42LE Shudder During EMCC Shift > Page 4512 This repair involves changing the transaxle fluid and filter, driving the vehicle 10 miles and changing the transaxle fluid a second time. 1. Raise the vehicle on a hoist. 2. Clean the transaxle oil pan area and adjoining surfaces. 3. Loosen the transaxle oil pan and drain the fluid into a suitable container. 4. Remove the pan and clean all sealant form the pan and transaxle mating surfaces. Clean the inside of the pan and magnet. 5. Separate the filter and 0-ring from the valve body. Inspect the 0-ring for cuts or improper installation which can lead to delayed garage shifts. 6. Install a new filter p/n 04796730 (42LE) or p/n 04864505 (41TE). Replace the 0-ring p/n 06032780 as necessary. 7. Apply a 1/8 inch bead of Mopar RTV Sealant p/n 82300234 to the mounting flange of the transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to the transaxle and torque the bolts to 19 Nm (165 in. Lbs.). 8. Lower the vehicle and add 4 quarts of Mopar ATF +2 Type 7176 transaxle fluid p/n 04798233 through the transaxle fill tube. 9. Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied, press your foot on the service brake and cycle the transaxle from park to all gear positions ending in neutral or park. 10. Check the transaxle fluid level and add an appropriate amount to bring the level to 3 mm (1/8 in.) below the ADD mark on the dipstick. 11. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range. 12. Drive the vehicle a minimum of 10 miles. 13. Repeat steps 1 through 4. 14. Separate the filter from the valve body to allow additional fluid to drain from the transaxle. Inspect the filter 0-ring for any damage and replace if necessary. 15. After the transaxle has stopped draining, re-install the filter and 0-ring. 16. Complete re-assembly and filling of the transaxle by following steps 7 through 11. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature Fluid Filter - A/T: All Technical Service Bulletins A/T - Slips In Reverse At Low Temperature NO: 21-06-96 GROUP: Transmission DATE: Apr. 26, 1996 SUBJECT: Slips In Reverse At Low Temperature MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS PROCEDURE APPLIES TO VEHICLES WITH 30TH OR 31ST TRANSAXLES BUILT BEFORE APR. 7, 1995 (TRANSAXLE IDENTIFICATION CODE NUMBER XXX-2306-XXXX). SYMPTOM/CONDITION: Transaxle slips during Reverse engagement after the vehicle has set in an ambient temperature below 20°F (-60°C) for at least 8 hours. Slipping that lasts up to 5 seconds under these temperature/time conditions is considered normal. DIAGNOSIS: If the vehicle operator describes the above symptom/condition, perform the Repair Procedure. If the transaxle also slips going into Drive, further diagnosis is required. PARTS REQUIRED: 1 4659837 Piston, Low/Reverse Servo AR 4318025 Sealant, RTV AR 4467721 Fluid, Mopar Automatic Transmission Type 7176 1 4269649 Filter, Transaxle 1 4269671 Gasket, Transaxle Filter REPAIR PROCEDURE: This bulletin involves installing a revised Low/Reverse servo piston. 1. Raise the vehicle with an appropriate hoist. 2. Clean the transaxle oil pan and mating area thoroughly, preferably with steam. 3. Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and clean the inside the oil pan and magnet. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 4517 4. Using special tool C-4553, remove the 2 screws attaching the transaxle oil filter. Separate the transaxle oil filter and gasket from the valve body and discard (refer to Figure 1). 5. Remove the parking rod E-clip and disconnect the parking rod from the valve body (refer to Figure 2). 6. Remove the neutral start/back-up lamp switch (refer to Figure 3). 7. Remove the seven valve body attaching bolts and separate the valve body and governor tubes from the transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 4518 8. Loosen the Low/Reverse band adjustment (refer to Figure 4). Disassemble the Low/Reverse servo (refer to Figures 5, 6 and 7). 9. Install the revised Low/Reverse piston (P/N 4659837) and reassemble the Low/Reverse servo assembly. 10. Using an inch-pound torque wrench, tighten the low/reverse band adjusting screw to 41 in. lbs. (4.6 Nm) then back the screw off 3 1/2 turns. Tighten the lock nut to 10 ft. lbs. (14 Nm). 11. Attach the valve body to the transaxle assembly, torque the seven attaching bolts to 105 in. lbs. (12 Nm). 12. Install and torque the neutral start/back-up lamp switch to 24 ft. lbs. (33 Nm). 13. Attach the parking rod to the valve body with the parking rod E-clip. 14. Install a new transaxle oil filter & transaxle oil filter gasket (P/N 4269649 & 4269671), torque the 2 attaching screws to 40 in. lbs. (5 Nm). 15. Apply Mopar RTV Sealant (P/N 4318025) to the mating surface of the transmission oil pan and the underside of the attaching bolt heads. Install the transmission oil pan and torque the bolts to 165 in. lbs. (19 Nm). 16. Pour four quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. 17. Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. 18. Add an appropriate a mount of transmission fluid to bring the level to 118 in. (3 mm) below the ADD mark on dipstick. 19. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 210696 > Apr > 96 > A/T - Slips In Reverse At Low Temperature > Page 4519 Labor Operation No: 21-80-10-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-05-97 > Mar > 97 > A/T - 41TE/42LE Shudder During EMCC Shift Technical Service Bulletin # 21-05-97 Date: 970314 A/T - 41TE/42LE Shudder During EMCC Shift NO: 21-05-97 GROUP: Transmission DATE: Mar. 14, 1997 SUBJECT: 41TE/42LE Transaxle Shudder During an EMCC (Electronically Modulated Converter Clutch) Shift MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: 1989 TO 1995 MODELS SHOULD HAVE TSB 18-24-95 PERFORMED PRIOR TO PROCEEDING WITH THIS REPAIR PROCEDURE. SYMPTOM/CONDITION: Transaxle shudder during a 3rd gear to 3rd gear partial EMCC (Electronically Modulated Converter Clutch) engagement, 3rd gear partial EMCC to 4th gear partial EMCC engagement, or 4th gear to 4th gear EMCC engagement. Vehicle speed will be above 40 mph to obtain these shift points. This condition can be the result of worn out automatic transaxle fluid, using additives in the transaxle fluid, or from using the wrong type fluid (Dexron II, III, or Mercon) in the transaxle. NOTE: MOPAR ATF+2 TYPE 7176 IS THE ONLY RECOMMENDED FLUID FOR THESE TRANSAXLES. DIAGNOSIS: Bring the vehicle to normal operating temperatures. Drive the vehicle on a smooth road while accelerating through the gears with light throttle application. Pay particular attention during the EMCC shifts that take place between 3rd and 4th gears above 40 mph. If vehicle shudder is noticed during the shifts, perform the Repair Procedure. PARTS REQUIRED: 1 04864505 Filter, 41TE Transaxle 1 04796730 Filter, 42LE Transaxle AR(1) 06032780 0-Ring, Filter AR 04798233 Oil, ATF+2 Type 7176 (Qts) AR(1) 82300234 Sealant, RTV POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-55-01-96 1.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-05-97 > Mar > 97 > A/T - 41TE/42LE Shudder During EMCC Shift > Page 4525 This repair involves changing the transaxle fluid and filter, driving the vehicle 10 miles and changing the transaxle fluid a second time. 1. Raise the vehicle on a hoist. 2. Clean the transaxle oil pan area and adjoining surfaces. 3. Loosen the transaxle oil pan and drain the fluid into a suitable container. 4. Remove the pan and clean all sealant form the pan and transaxle mating surfaces. Clean the inside of the pan and magnet. 5. Separate the filter and 0-ring from the valve body. Inspect the 0-ring for cuts or improper installation which can lead to delayed garage shifts. 6. Install a new filter p/n 04796730 (42LE) or p/n 04864505 (41TE). Replace the 0-ring p/n 06032780 as necessary. 7. Apply a 1/8 inch bead of Mopar RTV Sealant p/n 82300234 to the mounting flange of the transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to the transaxle and torque the bolts to 19 Nm (165 in. Lbs.). 8. Lower the vehicle and add 4 quarts of Mopar ATF +2 Type 7176 transaxle fluid p/n 04798233 through the transaxle fill tube. 9. Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied, press your foot on the service brake and cycle the transaxle from park to all gear positions ending in neutral or park. 10. Check the transaxle fluid level and add an appropriate amount to bring the level to 3 mm (1/8 in.) below the ADD mark on the dipstick. 11. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range. 12. Drive the vehicle a minimum of 10 miles. 13. Repeat steps 1 through 4. 14. Separate the filter from the valve body to allow additional fluid to drain from the transaxle. Inspect the filter 0-ring for any damage and replace if necessary. 15. After the transaxle has stopped draining, re-install the filter and 0-ring. 16. Complete re-assembly and filling of the transaxle by following steps 7 through 11. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Drain and Refill Fluid Filter - A/T: Service and Repair Fluid Drain and Refill 1. Raise vehicle on a hoist. 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. 4. Clean the oil pan and magnet. Reinstall pan using new MOPAR RTV sealant. Tighten oil pan bolts to 19 Nm (165 inch lbs.). 5. Pour four quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602 through the fill tube. 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. Add sufficient fluid to bring level to 1/8 inch below the ADD mark. CAUTION: Do not overfill transaxle. Do not acid oil if level is between: Lower holes for warm oil (100°F). Upper holes for hot oil (180°F). 8. Recheck fluid level after transaxle is at normal operating temperature. The level should be in the HOT region. 9. To prevent dirt from entering transaxle, make certain that dipstick is seated into the dipstick fill tube. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Drain and Refill > Page 4528 Fluid Filter - A/T: Service and Repair Fluid & Filter Change When the factory fill fluid is changed, only fluids labeled MOPAR ATF Plus 4 (Automatic Transmission fluid) Type 7176, or equivalent should be used. A filter change should be made at the time of the oil change. Also the magnet (on the inside of the oil pan) should be cleaned with a clean, dry cloth. If the transaxle is disassembled for any reason, the fluid and filter should be changed. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4537 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4538 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4539 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 18-09-97 > Feb > 97 > Converter Clutch - Vehicle Shudder on Lock Up Fluid Pump: Customer Interest Converter Clutch - Vehicle Shudder on Lock Up NO: 18-09-97 GROUP: Vehicle Performance DATE: Feb. 28, 1997 SUBJECT: Vehicle Shudder During Torque Convertor EMCC (Lock-up) Operation/Diagnostic Trouble Code 38 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-17-96 REV. B, DATED OCT. 4, 1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1996 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-97010). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE LABOR OPERATION CHANGES. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1990 - 1991 (AQ) Chrysler TC 1989 - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Avenger/Sebring/Talon 1996 (GS) Chrysler Voyager (International Market) 1995 - 1996 (JA) Cirrus/Stratus 1996 (JX) Sebring Convertible 1993 - 1996 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: NOTE: DIAGNOSTIC TROUBLE CODE (DTC) 38 (TORQUE CONVERTER CONTROL OUT OF RANGE) MUST BE PRESENT FOR THIS BULLETIN TO APPLY. IF DTC 38 IS NOT PRESENT AND THE VEHICLE IS A 1989-95 MODEL, REFER TO TECHNICAL SERVICE BULLETIN 18-24-95 DATED JUNE 24, 1995 AND PERFORM AS NECESSARY. IF DTC 38 IS NOT PRESENT AND THE VEHICLE IS A 1996 MODEL, REFER TO TECHNICAL SERVICE BULLETIN 21-05-96 DATED APR. 26, 1996 AND PERFORM AS NECESSARY. Vehicle shudders during full lock-up Electronically Modulated Convertor Clutch (EMCC) operation and DTC 38 is present. Full lock-up EMCC is indicated by 3LU or 4LU on the DRB III RPM display screen. DIAGNOSIS: This shudder condition can be the result of leakage in the transmission front pump caused by a worn pump bushing. It is sometimes accompanied by pump whine. Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC 38 is present, perform the Repair Procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 18-09-97 > Feb > 97 > Converter Clutch - Vehicle Shudder on Lock Up > Page 4544 PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the transmission front pump assembly and the transmission torque converter with one that has bonded converter clutch friction material and verifying the Transmission Control Module (TCM) part number. 1. Following the procedures outlined in the appropriate Service Manual, replace the torque converter and the transmission front pump assembly with the parts identified in the Parts Required section of this bulletin. 2. Perform the transmission oil cooler and lines reverse flushing and flow check procedure as outlined in the appropriate Service Manual. 3. Verify the TCM is the appropriate part number listed: 4. For 1989 - 1995 vehicles that do not have the appropriate TCM part number listed above, perform REPAIR PROCEDURE NO. 1 of Technical Service Bulletin 18-24-95. For 1996 vehicles that do not have the appropriate TCM part number listed above, perform the Repair Procedure of Technical Service Bulletin 21-05-96. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-60-05-91 1989 - 1995 AA,AC,AG,AJ,AP,AQ,AS,AY,ES,GS,NS **4.0** Hrs. 1993 - 1996 FJ,LH **4.7** Hrs. 1995 - 1996 JA,JX **5.7** Hrs. Supplemental Labor Operation No.'s 21-00-05-63 1989 - 1995 AS (Anti-Lock Brake System Equipped) 0.2 Hrs. 21-00-05-64 1991 - 1995 AS (All Wheel Drive Equipped) 1.2 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 18-09-97 > Feb > 97 > Converter Clutch - Vehicle Shudder on Lock Up > Page 4545 If it is necessary to perform step 4, use the Labor Operation No. called out in the appropriate referenced Technical Service Bulletin. FAILURE CODE: 52 - Improperly Machined Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 180594 > Apr > 94 > TCC Acceleration Shudder/DTC 38 Set Fluid Pump: Customer Interest TCC - Acceleration Shudder/DTC 38 Set NO: 18-05-94 GROUP: Vehicle Performance DATE: Apr. 8, 1994 SUBJECT: Vehicle Shudder During Torque Convertor EMCC Operation MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Voyager/Town & Country 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built After MDH 02-08-92) 1993 - 1994 (LH) Concorde/Intrepid/Vision 1994 (LH) LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Light to moderate acceleration shudder during torque converter EMCC (Electronic Modulated Converter Clutch) operation. Most noticeable on smooth roads, or on long, moderate uphill grades (depending on final drive ratio, approximately 28 to 42 MPH). This shudder condition is generally the result of leakage in the transmission front pump caused by a worn pump bushing. It is sometimes accompanied by pump whine and Diagnostic Trouble Code 38 (Torque Converter Control Out of Range). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II or III) with appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If Diagnostic Trouble Code 38 is present, proceed to the repair procedure. If no codes are present and all systems are functioning correctly, proceed with the following: A. Inspect the engine mounts for signs of deterioration or grounding. Repair or replace as necessary. B. Inspect all rotating components such as halfshafts, brake rotors, tires and wheels for any abnormal conditions that could contribute to low frequency vibrations. C. Road test the vehicle at normal operating temperatures while monitoring transmission performance using a DRB II or III. Use the RPM display screen, in the transmission diagnostic section, to display converter clutch function and throttle angle. EMCC shudder generally is encountered at 10 to 15 degrees throttle on smooth roads between 38 to 42 MPH depending on final drive ratio. The PRNDL readout on the DRB II or III can be either "3PL" or "4PL" during the shudder. To verify that the shudder is EMCC induced, the EMCC feature should be disengaged. This can be done by accelerating at medium/heavy throttle, or lightly depressing the brake pedal, or disengaging the throttle. If after doing any of these and the shudder disappears, go to the repair procedure. PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 180594 > Apr > 94 > TCC Acceleration Shudder/DTC 38 Set > Page 4550 REPAIR PROCEDURE: This bulletin involves replacing the transmission front pump assembly and the transmission torque converter with one that has bonded converter clutch friction material. 1. Following the procedures outlined in the appropriate Service Manual, replace the torque converter and the transmission front pump assembly with the parts identified in the parts section of this bulletin. 2. Perform the transmission oil cooler and lines reverse flushing and flow check procedure as outlined in the appropriate Service Manual. 3. Before performing the torque converter clutch break in reset procedure verify that the repair has corrected the shudder condition. Drive the vehicle under the same conditions that caused the shudder. If the condition is corrected, go to step four. NOTE: SOME LIGHT SHUDDER MAY BE PRESENT BEFORE RESETTING THE EMCC BREAK-IN PROCEDURE. If severe shudder is still present, refer to the diagnostic section of this bulletin and re-evaluate the items listed. 4. Using the DRB II or III Scan Tool, perform the Torque Converter Clutch Break-in Procedure listed in the appropriate Service Manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-60-05-91 1993 - 1994 AA, AC, AG, AP, AS & 1992 - 1993 AY 6.1 Hrs. 1993 - 1994 LH 7.1 Hrs. 21-00-05-63 1993 - 1994 AS (Anti-Lock Brake System Equipped) 0.2 Hrs. 21-00-05-64 1993 - 1994 AS (All Wheel Drive Equipped) 1.2 Hrs. FAILURE CODE: 52 - Improperly Machined Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4556 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4557 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4558 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 18-09-97 > Feb > 97 > Converter Clutch - Vehicle Shudder on Lock Up Fluid Pump: All Technical Service Bulletins Converter Clutch - Vehicle Shudder on Lock Up NO: 18-09-97 GROUP: Vehicle Performance DATE: Feb. 28, 1997 SUBJECT: Vehicle Shudder During Torque Convertor EMCC (Lock-up) Operation/Diagnostic Trouble Code 38 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-17-96 REV. B, DATED OCT. 4, 1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1996 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-97010). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE LABOR OPERATION CHANGES. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1990 - 1991 (AQ) Chrysler TC 1989 - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Avenger/Sebring/Talon 1996 (GS) Chrysler Voyager (International Market) 1995 - 1996 (JA) Cirrus/Stratus 1996 (JX) Sebring Convertible 1993 - 1996 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: NOTE: DIAGNOSTIC TROUBLE CODE (DTC) 38 (TORQUE CONVERTER CONTROL OUT OF RANGE) MUST BE PRESENT FOR THIS BULLETIN TO APPLY. IF DTC 38 IS NOT PRESENT AND THE VEHICLE IS A 1989-95 MODEL, REFER TO TECHNICAL SERVICE BULLETIN 18-24-95 DATED JUNE 24, 1995 AND PERFORM AS NECESSARY. IF DTC 38 IS NOT PRESENT AND THE VEHICLE IS A 1996 MODEL, REFER TO TECHNICAL SERVICE BULLETIN 21-05-96 DATED APR. 26, 1996 AND PERFORM AS NECESSARY. Vehicle shudders during full lock-up Electronically Modulated Convertor Clutch (EMCC) operation and DTC 38 is present. Full lock-up EMCC is indicated by 3LU or 4LU on the DRB III RPM display screen. DIAGNOSIS: This shudder condition can be the result of leakage in the transmission front pump caused by a worn pump bushing. It is sometimes accompanied by pump whine. Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC 38 is present, perform the Repair Procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 18-09-97 > Feb > 97 > Converter Clutch - Vehicle Shudder on Lock Up > Page 4563 PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the transmission front pump assembly and the transmission torque converter with one that has bonded converter clutch friction material and verifying the Transmission Control Module (TCM) part number. 1. Following the procedures outlined in the appropriate Service Manual, replace the torque converter and the transmission front pump assembly with the parts identified in the Parts Required section of this bulletin. 2. Perform the transmission oil cooler and lines reverse flushing and flow check procedure as outlined in the appropriate Service Manual. 3. Verify the TCM is the appropriate part number listed: 4. For 1989 - 1995 vehicles that do not have the appropriate TCM part number listed above, perform REPAIR PROCEDURE NO. 1 of Technical Service Bulletin 18-24-95. For 1996 vehicles that do not have the appropriate TCM part number listed above, perform the Repair Procedure of Technical Service Bulletin 21-05-96. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-60-05-91 1989 - 1995 AA,AC,AG,AJ,AP,AQ,AS,AY,ES,GS,NS **4.0** Hrs. 1993 - 1996 FJ,LH **4.7** Hrs. 1995 - 1996 JA,JX **5.7** Hrs. Supplemental Labor Operation No.'s 21-00-05-63 1989 - 1995 AS (Anti-Lock Brake System Equipped) 0.2 Hrs. 21-00-05-64 1991 - 1995 AS (All Wheel Drive Equipped) 1.2 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 18-09-97 > Feb > 97 > Converter Clutch - Vehicle Shudder on Lock Up > Page 4564 If it is necessary to perform step 4, use the Labor Operation No. called out in the appropriate referenced Technical Service Bulletin. FAILURE CODE: 52 - Improperly Machined Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 180594 > Apr > 94 > TCC - Acceleration Shudder/DTC 38 Set Fluid Pump: All Technical Service Bulletins TCC - Acceleration Shudder/DTC 38 Set NO: 18-05-94 GROUP: Vehicle Performance DATE: Apr. 8, 1994 SUBJECT: Vehicle Shudder During Torque Convertor EMCC Operation MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Voyager/Town & Country 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built After MDH 02-08-92) 1993 - 1994 (LH) Concorde/Intrepid/Vision 1994 (LH) LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Light to moderate acceleration shudder during torque converter EMCC (Electronic Modulated Converter Clutch) operation. Most noticeable on smooth roads, or on long, moderate uphill grades (depending on final drive ratio, approximately 28 to 42 MPH). This shudder condition is generally the result of leakage in the transmission front pump caused by a worn pump bushing. It is sometimes accompanied by pump whine and Diagnostic Trouble Code 38 (Torque Converter Control Out of Range). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II or III) with appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If Diagnostic Trouble Code 38 is present, proceed to the repair procedure. If no codes are present and all systems are functioning correctly, proceed with the following: A. Inspect the engine mounts for signs of deterioration or grounding. Repair or replace as necessary. B. Inspect all rotating components such as halfshafts, brake rotors, tires and wheels for any abnormal conditions that could contribute to low frequency vibrations. C. Road test the vehicle at normal operating temperatures while monitoring transmission performance using a DRB II or III. Use the RPM display screen, in the transmission diagnostic section, to display converter clutch function and throttle angle. EMCC shudder generally is encountered at 10 to 15 degrees throttle on smooth roads between 38 to 42 MPH depending on final drive ratio. The PRNDL readout on the DRB II or III can be either "3PL" or "4PL" during the shudder. To verify that the shudder is EMCC induced, the EMCC feature should be disengaged. This can be done by accelerating at medium/heavy throttle, or lightly depressing the brake pedal, or disengaging the throttle. If after doing any of these and the shudder disappears, go to the repair procedure. PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 180594 > Apr > 94 > TCC - Acceleration Shudder/DTC 38 Set > Page 4569 REPAIR PROCEDURE: This bulletin involves replacing the transmission front pump assembly and the transmission torque converter with one that has bonded converter clutch friction material. 1. Following the procedures outlined in the appropriate Service Manual, replace the torque converter and the transmission front pump assembly with the parts identified in the parts section of this bulletin. 2. Perform the transmission oil cooler and lines reverse flushing and flow check procedure as outlined in the appropriate Service Manual. 3. Before performing the torque converter clutch break in reset procedure verify that the repair has corrected the shudder condition. Drive the vehicle under the same conditions that caused the shudder. If the condition is corrected, go to step four. NOTE: SOME LIGHT SHUDDER MAY BE PRESENT BEFORE RESETTING THE EMCC BREAK-IN PROCEDURE. If severe shudder is still present, refer to the diagnostic section of this bulletin and re-evaluate the items listed. 4. Using the DRB II or III Scan Tool, perform the Torque Converter Clutch Break-in Procedure listed in the appropriate Service Manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-60-05-91 1993 - 1994 AA, AC, AG, AP, AS & 1992 - 1993 AY 6.1 Hrs. 1993 - 1994 LH 7.1 Hrs. 21-00-05-63 1993 - 1994 AS (Anti-Lock Brake System Equipped) 0.2 Hrs. 21-00-05-64 1993 - 1994 AS (All Wheel Drive Equipped) 1.2 Hrs. FAILURE CODE: 52 - Improperly Machined Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 4570 Fluid Pump: Description and Operation The oil pump is located in the pump housing inside of the bell housing of the transaxle case, and is similar to oil pumps used in other Chrysler applications. The inner gear is driven by the torque converter impeller hub. Torque is supplied to the impeller hub by the engine crankshaft through the flex plate and converter housing. As the gears rotate, the clearance between the gear teeth increases in the crescent area, and creates a suction at the inlet side of the pump. Fluid is pulled through the pump inlet from the oil pan. As the clearance between the gear teeth in the crescent area decreases, it forces fluid into the pump outlet. The pressurized oil from the outlet operates the torque converter, clutches and the lubrication system. The pump is held in the housing by the reaction shaft support Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair Governor: Service and Repair The governor assembly can be removed for reconditioning or replacement without removing the transfer gear cover, transfer gear and governor support. To remove governor, drain transmission fluid and remove transmission oil pan. Remove valve body, unbolt governor from governor support, then remove governor. When cleaning or assembling the governor assembly, ensure governor valves move freely in governor body bores. 1. Remove rear cover attaching bolts and rear cover. Fig. 5 Transfer Shaft Gear Nut Removal 2. Using tool No. L-4434, or equivalent, remove transfer shaft gear retaining nut, Fig. 5. Fig. 6 Transfer Shaft Gear Removal 3. Using tool No. L-4407, or equivalent, remove transfer shaft gear and shim, Fig. 6. 4. Remove governor support retainer, then remove low-reverse band anchor pin. 5. Remove governor assembly. 6. Remove transfer shaft retainer snap ring, then using tool No. L-4512, or equivalent, and a puller, remove transfer shaft and retainer assembly. 7. Remove transfer shaft retainer from shaft. 8. Using a screwdriver, remove oil seal from transfer shaft retainer. 9. Tap new oil seal into shaft retainer. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Page 4574 10. Reverse procedure to install. Tighten nut and cover retaining bolts to specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Override Switch <--> [Overdrive Switch, A/T] > Component Information > Locations Overdrive Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Override Switch <--> [Overdrive Switch, A/T] > Component Information > Locations > Page 4578 Overdrive Off Switch (8 - Way) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation > General Information Planetary Gears: Description and Operation General Information The entire planetary gear-train is located behind the input clutch assembly and is inside the 2-4 and L/R clutch assemblies. The planetary gear-train consists of two sun gears, two planetary carriers, two annulus (ring) gears and one output shaft which is part of the rear carrier. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation > General Information > Page 4583 Planetary Gears: Description and Operation Front Carrier Assembly The front planetary carrier and gear annulus (ring) gear are splined together as one unit. When the overdrive clutch is applied, it drives the front carrier assembly by the overdrive hub. When the low/reverse clutch is applied, it holds or prevents the front carrier assembly from rotating. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation > General Information > Page 4584 Planetary Gears: Description and Operation Rear Carrier Assembly The rear planetary carrier, front annulus (ring) gear and output shaft are all one assembly. The rear carrier assembly provides all output power for the transaxle assembly. In other words, all output from the transaxle must go through the rear carrier. The lugs around the outside of the assembly have two purposes: - To engage the parking pawl when the driver selects park - To generate an output speed signal used by the TCM There are no clutches splined or connected to this unit in any way. The rear carrier assembly is supported to the case by two tapered roller bearings, which must be set up with specific preload and measured by turning torque. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4594 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4595 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4596 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4597 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4598 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4599 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Control Module: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 4604 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 4605 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts Control Module: Customer Interest A/T - Harsh Gear Engagement/Upshifts/Downshifts NO.: 21-36-93 GROUP: Transmission DATE: Dec. 10, 1993 SUBJECT: Improved Transmission Shift Schedule MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH 09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION. SYMPTOM/CONDITION: Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1 kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary Neutral/Drive garage shifts. Park to Reverse noise (grunt). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4686478 Transmission Control Module AR 4467721 Transmission Fluid - ATF Plus (7176) REPAIR PROCEDURE: This repair involves the replacement of the transmission control module with a module that incorporates revised software, changing the transmission fluid, setting the pinion factor, and transaxle quick learn. 1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is currently installed on the vehicle. This is accomplished by choosing the TSB option under Adjustments. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS INSPECTED AT THE RETURN CENTER. 2. Replace the transmission control module with the new module, following the procedures outlined in the appropriate service manual. 3. Change the transmission fluid following the procedure outlined in the service manual. NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER. 4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and then place gear selector in Neutral. 5. Using the procedures listed in the service manual complete the following: a. Quick Learn Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 4610 b. Electronic Pinion Factor Procedure 6. Drive the vehicle at least 10 miles. 7. Change the transmission fluid again following the procedure outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-06-90 2.1 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4616 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4617 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4618 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4619 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4620 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 4621 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Control Module: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 4626 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 4627 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts Control Module: All Technical Service Bulletins A/T - Harsh Gear Engagement/Upshifts/Downshifts NO.: 21-36-93 GROUP: Transmission DATE: Dec. 10, 1993 SUBJECT: Improved Transmission Shift Schedule MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH 09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION. SYMPTOM/CONDITION: Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1 kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary Neutral/Drive garage shifts. Park to Reverse noise (grunt). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4686478 Transmission Control Module AR 4467721 Transmission Fluid - ATF Plus (7176) REPAIR PROCEDURE: This repair involves the replacement of the transmission control module with a module that incorporates revised software, changing the transmission fluid, setting the pinion factor, and transaxle quick learn. 1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is currently installed on the vehicle. This is accomplished by choosing the TSB option under Adjustments. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS INSPECTED AT THE RETURN CENTER. 2. Replace the transmission control module with the new module, following the procedures outlined in the appropriate service manual. 3. Change the transmission fluid following the procedure outlined in the service manual. NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER. 4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and then place gear selector in Neutral. 5. Using the procedures listed in the service manual complete the following: a. Quick Learn Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 4632 b. Electronic Pinion Factor Procedure 6. Drive the vehicle at least 10 miles. 7. Change the transmission fluid again following the procedure outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-06-90 2.1 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor Axle Ratio Values Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values NO.: 08-39-93 Rev. A GROUP: Electrical DATE: Sep. 17, 1993 SUBJECT: 41TE Pinion Factor Axle Ratio Values NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** MODELS: **1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue ** DISCUSSION: When installing a replacement TCM (Transmission Control Module), it is necessary to set the pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the speedometer indicates correctly. One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the correct axle ratios for the various applications: YEAR ENGINE SIZE RATIO 1993 3.8L 3.19 3.0L and 3.3L 3.62 1994 3.8L 3.45 3.0L and 3.3L 3.62 POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor Axle Ratio Values Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values NO.: 08-39-93 Rev. A GROUP: Electrical DATE: Sep. 17, 1993 SUBJECT: 41TE Pinion Factor Axle Ratio Values NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** MODELS: **1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue ** DISCUSSION: When installing a replacement TCM (Transmission Control Module), it is necessary to set the pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the speedometer indicates correctly. One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the correct axle ratios for the various applications: YEAR ENGINE SIZE RATIO 1993 3.8L 3.19 3.0L and 3.3L 3.62 1994 3.8L 3.45 3.0L and 3.3L 3.62 POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module Transmission Control Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 4644 Power Control Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 4645 Control Module: Locations Power Distribution Center Power Distribution Center Fuse Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4648 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4649 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4650 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4651 Control Module: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4652 Control Module: Connector Views Part 1 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4653 Part 2 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4654 Part 3 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4655 Part 4 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4656 Part 5 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4657 Part 6 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4658 Part 7 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4659 Part 8 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4660 Part 9 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4661 Part 10 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4662 Part 11 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4663 Transmission Control Schematic Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information Control Module: Description and Operation General Information Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4666 The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transaxle. The TCM receives information from several inputs, and selects the operational mode of the transaxle. Some of the inputs are used only by the TCM, while others are shared with other control modules on the CCD Bus. Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for operating conditions. This is to determine the desired gear range the transaxle must be operated in. The actual shift points within each shift schedule have been predetermined for the best transaxle operation, and are stored in the TCM's ROM memory. Once a TCM is installed during service, the following procedures must be performed: - Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the vehicle - Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes and final drive ratios on 1993 and newer vehicles The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the TCM learning process. The vehicle must still be driven and shifted several times in each gear range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool. NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module display on the DRB III scan tool Emission regulations require the use of two labels after a flash update: - Emission Modification Label - Emission Part Number Modification Label The following provides information on TCM identification and flash programming application: 1989 - 92 Original controllers were non-finned and are non-flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit 1993 - 95 Original controllers were finned with four heat sinks and are flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This TSB also lists the 1990 vehicles that require a wiring modification to pin 49. 1996 - Original controllers were finned with seven heat sinks and are flashable - Replacement controllers have fins with seven heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the common DLC Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4667 Control Module: Description and Operation Electronic Transmission Controller Operation LOCATION The EATX control module is located under the hood, in a potted, die cast aluminum housing with a sealed, 60-way connector. ADAPTIVE CONTROLS These controls function by reading the input and output speeds over 140 times a second and responding to each new reading. - This provides the precise friction element control needed to make smooth clutch-to-clutch shifts for all gear changes. As with most automatic transaxles, all shifts involve releasing one element and applying a different element. - In simplified terms, the upshift logic allows the releasing element to slip backwards slightly, to ensure that it does not have excess capacity; the apply element is filled until it begins to make the speed change to the higher gear; its apply pressure is then controlled to maintain the desired rate of speed change until the shift is complete. The key to providing excellent shift quality is precision; EXAMPLE As mentioned, the release element for upshifts is allowed to slip backwards slightly; the amount of that slip is typically less than a total of 20 degrees. LEARNING To achieve that precision, the EATX control module learns the characteristics of the particular transaxle that it is controlling. - It learns the release rate of the releasing element and the apply time of the applying element. - It also learns the rate at which the apply element builds pressure sufficient to begin making the speed change. - This method achieves more precision than would be possible with exacting tolerances. It can also adapt to any changes that occur with age or environment, for example, altitude, temperature, engine output, etc. KICKDOWN SHIFTING For kickdown shifts, the control logic allows the releasing element to slip and then controls the rate at which the input (and engine) accelerate; when the lower gear speed is achieved, the releasing element reapplies to maintain that speed until the apply element is filled. This provides quick response since the engine begins to accelerate immediately and a smooth torque exchange since the release element can control the rate of torque increase. This control can make any power train feel more responsive without increasing harshness. SUMMARY Adaptive controls respond to input speed changes They compensate for changes in engine or friction element torque and provide good, consistent shift quality for the life of the transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information Control Module: Service and Repair General Information Do not interchange Transmission Control Modules with previous-year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: - Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information > Page 4670 Control Module: Service and Repair Replacement NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner. REMOVAL 1. Disconnect the battery negative cable. 2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect the 60 way connector on Transmission Control Module. 3. Remove Transmission Control Module mounting screws and lift module from vehicle. INSTALLATION To install, reverse removal procedures. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Transmission Control Relay Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Transmission Control Relay > Page 4675 Transmission Control System Relay: Locations Transmission (Safety Shut-Down) Relay Transmission Relay Location The Transmission Relay is located in LH side of engine compartment in the Power Distribution Center. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Transmission Control Relay > Page 4676 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4677 Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations > Page 4682 Back Up Lamp Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4691 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4692 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4693 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-05-99A > Sep > 99 > A/T Pan Gasket - Reusable Design/Installation Technical Service Bulletin # 21-05-99A Date: 990903 A/T Pan Gasket - Reusable Design/Installation NUMBER: 21-05-99 Rev. A GROUP: Transmission DATE: Sep. 03, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-05-99 DATED MARCH 5, 1999 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND MODEL COVERAGE. SUBJECT: Reusable Automatic Transmission Oil Pan Gasket OVERVIEW: This bulletin announces availability and installation of a reusable automatic transmission oil pan gasket. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon **1989** - 1993 (AG) Daytona **1989** - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1989** - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (European Market) 1995 - **2000** (JA) Cirrus/Stratus/Breeze 1996 - **2000** (JX) Sebring Convertible **1993 - 2000 (LH) Concorde/Intrepid/New Yorker/LHS/Vision/300M** 1996 - **2000** (NS) Town & Country/Caravan/Voyager **1995 - 2000 (PL) Neon** **1997 - 2000 (PR) Prowler** DISCUSSION: A reusable silicone gasket has been developed to replace the RTV method of sealing the automatic transmission oil pan. Due to more frequent Automatic Transmission Fluid (ATF) change intervals and the possibility of the fluid foaming if it comes in contact with uncured RTV it is recommended that this gasket be used in all applications. NOTE: THIS GASKET CAN BE REUSED UP TO THREE (3) TIMES. PARTS REQUIRED: **1 05011113AA Gasket, Transmission Oil Pan, 31TH** **1 05011114AA Gasket, Transmission Oil Pan, 42LE** 1 05011115AA Gasket, Transmission Oil Pan, 41TE/AE POLICY: INFORMATION ONLY POLICY: Information Only Installation Procedure 1. With oil pan removed from transmission case for routine service or transmission repair proceed to step # 2. 2. Clean any residue from oil pan and magnet. 3. Replace O-ring and filter on bottom of valve body. 4. Using a plastic or wooden scraper, remove old RTV from transmission case rails. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-05-99A > Sep > 99 > A/T Pan Gasket - Reusable Design/Installation > Page 4699 CAUTION: ALUMINUM COMPONENTS ARE VERY SUSCEPTABLE TO METAL TRANSFER WHEN OLD GASKET MATERIAL IS REMOVED FROM THEM. USE EXTREME CARE WHEN CLEANING THESE COMPONENTS. 5. Apply thin coat of transmission fluid to oil pan and transmission case pan rails. 6. Orient reusable gasket properly with bolt holes and assemble oil pan and gasket to transmission case. Tighten oil pan bolts to 19 Nm (165 in lbs.). 7. Refill transmission to the proper level with MOPAR ATF + 3 Type 7176, p/n 05010124AA, or MOPAR ATF +4 Type 9602, p/n 05013457AA, for 1999 JA/LH/PR vehicles. CAUTION: DO NOT OVERFILL TRANSAXLE. DO NOT ADD OIL IF LEVEL IS BETWEEN: LOWER HOLES FOR WARM OIL (100°F). UPPER HOLES FOR HOT OIL (180°F.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4704 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4705 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4706 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 21-05-99A > Sep > 99 > A/T Pan Gasket - Reusable Design/Installation Technical Service Bulletin # 21-05-99A Date: 990903 A/T Pan Gasket - Reusable Design/Installation NUMBER: 21-05-99 Rev. A GROUP: Transmission DATE: Sep. 03, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-05-99 DATED MARCH 5, 1999 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND MODEL COVERAGE. SUBJECT: Reusable Automatic Transmission Oil Pan Gasket OVERVIEW: This bulletin announces availability and installation of a reusable automatic transmission oil pan gasket. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon **1989** - 1993 (AG) Daytona **1989** - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1989** - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (European Market) 1995 - **2000** (JA) Cirrus/Stratus/Breeze 1996 - **2000** (JX) Sebring Convertible **1993 - 2000 (LH) Concorde/Intrepid/New Yorker/LHS/Vision/300M** 1996 - **2000** (NS) Town & Country/Caravan/Voyager **1995 - 2000 (PL) Neon** **1997 - 2000 (PR) Prowler** DISCUSSION: A reusable silicone gasket has been developed to replace the RTV method of sealing the automatic transmission oil pan. Due to more frequent Automatic Transmission Fluid (ATF) change intervals and the possibility of the fluid foaming if it comes in contact with uncured RTV it is recommended that this gasket be used in all applications. NOTE: THIS GASKET CAN BE REUSED UP TO THREE (3) TIMES. PARTS REQUIRED: **1 05011113AA Gasket, Transmission Oil Pan, 31TH** **1 05011114AA Gasket, Transmission Oil Pan, 42LE** 1 05011115AA Gasket, Transmission Oil Pan, 41TE/AE POLICY: INFORMATION ONLY POLICY: Information Only Installation Procedure 1. With oil pan removed from transmission case for routine service or transmission repair proceed to step # 2. 2. Clean any residue from oil pan and magnet. 3. Replace O-ring and filter on bottom of valve body. 4. Using a plastic or wooden scraper, remove old RTV from transmission case rails. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 21-05-99A > Sep > 99 > A/T Pan Gasket - Reusable Design/Installation > Page 4712 CAUTION: ALUMINUM COMPONENTS ARE VERY SUSCEPTABLE TO METAL TRANSFER WHEN OLD GASKET MATERIAL IS REMOVED FROM THEM. USE EXTREME CARE WHEN CLEANING THESE COMPONENTS. 5. Apply thin coat of transmission fluid to oil pan and transmission case pan rails. 6. Orient reusable gasket properly with bolt holes and assemble oil pan and gasket to transmission case. Tighten oil pan bolts to 19 Nm (165 in lbs.). 7. Refill transmission to the proper level with MOPAR ATF + 3 Type 7176, p/n 05010124AA, or MOPAR ATF +4 Type 9602, p/n 05013457AA, for 1999 JA/LH/PR vehicles. CAUTION: DO NOT OVERFILL TRANSAXLE. DO NOT ADD OIL IF LEVEL IS BETWEEN: LOWER HOLES FOR WARM OIL (100°F). UPPER HOLES FOR HOT OIL (180°F.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4713 Seals and Gaskets: By Symptom Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4714 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4715 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4716 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4717 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4718 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4719 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4720 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Page 4721 Seals and Gaskets: Service and Repair Remove Oil Pump Seal Install Oil Pump Seal Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Override Switch <--> [Overdrive Switch, A/T] > Component Information > Locations Overdrive Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Override Switch <--> [Overdrive Switch, A/T] > Component Information > Locations > Page 4726 Overdrive Off Switch (8 - Way) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4738 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4739 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4740 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 4746 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 4747 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4752 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4753 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4754 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4760 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4761 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4764 Park Neutral Position Switch / PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4765 Transmission Position Switch/Sensor: Locations 4 Speed A/T Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 4768 Park / Neutral Position Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 4771 Transmission Position Switch/Sensor: Description and Operation Switch, Transmission Range The white Transmission Range Switch (formerly called PRNDL) is used as an input to the Transmission Control Module, on the 4 speed electronic automatic transaxle. Note: The Transmission Range Sensor is a different component from the Transmission Range Switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 4774 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 4775 Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 4784 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4789 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4790 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4791 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 4797 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4802 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4803 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4804 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4805 Input / Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector Input Speed Sensor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector > Page 4808 Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4809 Transmission Speed Sensor: Description and Operation Three pressure switches incorporated in an assembly with the solenoids identify solenoid application. Two speed sensors read input (torque converter turbine) and output (parking sprag) speeds. Position switch indicates manual shift lever position. Engine speed, throttle position, temperature, etc., are also observed. - Some of these signals are read directly from the engine control sensors; others are read from a multiplex circuit with the powertrain control module. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4810 Transmission Speed Sensor: Testing and Inspection INPUT (TURBINE) SPEED SENSOR INSPECTION 1. Disconnect the input speed sensor connector. 2. Measure the resistance between the input speed sensor side connector terminals 1 and 2. Standard value: 0.3k - 1.2k ohms 3. If the resistance is outside the standard value, replace the input speed sensor. OUTPUT SPEED SENSOR INSPECTION 1. Disconnect the output speed sensor connector. 2. Measure the resistance between the input speed sensor side connector terminals I and 2. Standard value: 0.3k - 1.2k ohms 3. If the resistance is outside the standard value, replace the output speed sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4811 Transmission Speed Sensor: Service and Repair CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Input (Turbine) Speed Sensor INPUT The input speed sensor is located to the left of the manual shift lever. CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Output Speed Sensor OUTPUT The output speed sensor is located to the right of the manual shift lever. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T Ratcheting Sound When Coming To Stop Shift Solenoid: Customer Interest A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T Ratcheting Sound When Coming To Stop > Page 4823 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop Shift Solenoid: All Technical Service Bulletins A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 4829 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 4830 Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 4831 Transmission Solenoid Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair Selector Shaft: Service and Repair REMOVAL 1. Remove shift cable from lever. 2. Loosen the lever mounting bolt. Do not remove bolt (not necessary). 3. Pull up on lever and remove. INSTALLATION For installation, reverse removal procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments Shift Cable: Adjustments NOTE: When it is necessary to disassemble linkage cable from levers, plastic grommet retainers should always be replaced with new grommets. 1. Place gearshift lever in P position, then loosen clamp bolt on gearshift cable bracket. 2. On column shift models, ensure preload adjustment spring engages fork on transaxle bracket. 3. Pull the shift lever by hand all the way to the front detent position (P), then tighten lock screw to specification. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4839 Shift Cable: Service and Repair REMOVAL 1. Remove cable eyelet attachment from transaxle operating lever pin. 2. Using pliers, squeeze ears of cable conduit attachment at mounting bracket and push through hole to remove. 3. At the steering column attachment, remove the cable eyelet attachment from the shift lever pin. 4. Using pliers, squeeze ears of cable attachment at mounting bracket then push through hole to remove. 5. Unseat the dash grommet and remove the cable from the vehicle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4840 6. Remove the under instrument panel silencer. INSTALLATION 1. Install cable into steering column attachment bracket. Verify conduit ears are fully engaged. Verify cable does not interfere with brake pedal actuation. 2. Attach cable eyelet fitting onto shift lever pin. 3. Insert transaxle end of cable through dash panel hole and fully seat grommet 4. Install instrument panel silencer. Verify gearshift cable is routed through the slot in the silencer. CAUTION: Failure to route the cable properly at the silencer may cause brake pedal interference. 5. Attach transaxle end of cable to the mounting bracket on the transaxle. Assure the conduit attachment ears are fully seated. 6. Attach cable eyelet fitting onto the transaxle operating lever. 7. Complete adjustment using the gearshift cable adjustment procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Description and Operation > Front Sun Gear Assembly Sun Gear: Description and Operation Front Sun Gear Assembly The front sun gear assembly rides in the center of the front carrier, and is welded to the center of two hubs that are arranged back to back. Each of the hubs are splined to a clutch. The front-most hub is splined to the reverse clutch which turns the front sun gear when it is applied. The rearward hub is splined to the 2-4 clutch which prevents the front sun gear from turning when it is applied. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Description and Operation > Front Sun Gear Assembly > Page 4845 Sun Gear: Description and Operation Rear Sun Gear The rear sun gear is located in the center of the rear carrier assembly. There are two thrust bearings located on either side of the sun gear. When the underdrive clutch is applied, it drives the rear sun gear through the underdrive hub and shaft. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments Throttle Valve Cable/Linkage: Adjustments THROTTLE CABLE Fig. 3 Throttle Cable Adjustment 1. Perform adjustment with engine at operating temperature, then loosen cable mounting bracket lock screw, Fig. 3. 2. Position bracket with both alignment tabs touching transaxle cast surface, then tighten to specifications. 3. Release cross-lock on the cable assembly by pulling cross-lock upward. Cable must be free to slide completely toward engine to ensure proper adjustment. 4. Move transaxle throttle control lever fully clockwise against its internal stop, then press cross-lock downward into locked position. 5. Test cable operation by moving transaxle throttle lever forward, then slowly release it to ensure full return. THROTTLE ROD 1. Ensure engine is at normal operating temperature, then loosen adjustment swivel lock screw. Swivel must be free to slide along flat end of throttle rod. 2. Hold transaxle throttle lever firmly toward engine against internal stop and tighten swivel lock screw to specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter: > 180594 > Apr > 94 > TCC - Acceleration Shudder/DTC 38 Set Torque Converter: Customer Interest TCC - Acceleration Shudder/DTC 38 Set NO: 18-05-94 GROUP: Vehicle Performance DATE: Apr. 8, 1994 SUBJECT: Vehicle Shudder During Torque Convertor EMCC Operation MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Voyager/Town & Country 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built After MDH 02-08-92) 1993 - 1994 (LH) Concorde/Intrepid/Vision 1994 (LH) LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Light to moderate acceleration shudder during torque converter EMCC (Electronic Modulated Converter Clutch) operation. Most noticeable on smooth roads, or on long, moderate uphill grades (depending on final drive ratio, approximately 28 to 42 MPH). This shudder condition is generally the result of leakage in the transmission front pump caused by a worn pump bushing. It is sometimes accompanied by pump whine and Diagnostic Trouble Code 38 (Torque Converter Control Out of Range). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II or III) with appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If Diagnostic Trouble Code 38 is present, proceed to the repair procedure. If no codes are present and all systems are functioning correctly, proceed with the following: A. Inspect the engine mounts for signs of deterioration or grounding. Repair or replace as necessary. B. Inspect all rotating components such as halfshafts, brake rotors, tires and wheels for any abnormal conditions that could contribute to low frequency vibrations. C. Road test the vehicle at normal operating temperatures while monitoring transmission performance using a DRB II or III. Use the RPM display screen, in the transmission diagnostic section, to display converter clutch function and throttle angle. EMCC shudder generally is encountered at 10 to 15 degrees throttle on smooth roads between 38 to 42 MPH depending on final drive ratio. The PRNDL readout on the DRB II or III can be either "3PL" or "4PL" during the shudder. To verify that the shudder is EMCC induced, the EMCC feature should be disengaged. This can be done by accelerating at medium/heavy throttle, or lightly depressing the brake pedal, or disengaging the throttle. If after doing any of these and the shudder disappears, go to the repair procedure. PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter: > 180594 > Apr > 94 > TCC - Acceleration Shudder/DTC 38 Set > Page 4857 REPAIR PROCEDURE: This bulletin involves replacing the transmission front pump assembly and the transmission torque converter with one that has bonded converter clutch friction material. 1. Following the procedures outlined in the appropriate Service Manual, replace the torque converter and the transmission front pump assembly with the parts identified in the parts section of this bulletin. 2. Perform the transmission oil cooler and lines reverse flushing and flow check procedure as outlined in the appropriate Service Manual. 3. Before performing the torque converter clutch break in reset procedure verify that the repair has corrected the shudder condition. Drive the vehicle under the same conditions that caused the shudder. If the condition is corrected, go to step four. NOTE: SOME LIGHT SHUDDER MAY BE PRESENT BEFORE RESETTING THE EMCC BREAK-IN PROCEDURE. If severe shudder is still present, refer to the diagnostic section of this bulletin and re-evaluate the items listed. 4. Using the DRB II or III Scan Tool, perform the Torque Converter Clutch Break-in Procedure listed in the appropriate Service Manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-60-05-91 1993 - 1994 AA, AC, AG, AP, AS & 1992 - 1993 AY 6.1 Hrs. 1993 - 1994 LH 7.1 Hrs. 21-00-05-63 1993 - 1994 AS (Anti-Lock Brake System Equipped) 0.2 Hrs. 21-00-05-64 1993 - 1994 AS (All Wheel Drive Equipped) 1.2 Hrs. FAILURE CODE: 52 - Improperly Machined Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 180594 > Apr > 94 > TCC - Acceleration Shudder/DTC 38 Set Torque Converter: All Technical Service Bulletins TCC - Acceleration Shudder/DTC 38 Set NO: 18-05-94 GROUP: Vehicle Performance DATE: Apr. 8, 1994 SUBJECT: Vehicle Shudder During Torque Convertor EMCC Operation MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Voyager/Town & Country 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built After MDH 02-08-92) 1993 - 1994 (LH) Concorde/Intrepid/Vision 1994 (LH) LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Light to moderate acceleration shudder during torque converter EMCC (Electronic Modulated Converter Clutch) operation. Most noticeable on smooth roads, or on long, moderate uphill grades (depending on final drive ratio, approximately 28 to 42 MPH). This shudder condition is generally the result of leakage in the transmission front pump caused by a worn pump bushing. It is sometimes accompanied by pump whine and Diagnostic Trouble Code 38 (Torque Converter Control Out of Range). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II or III) with appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If Diagnostic Trouble Code 38 is present, proceed to the repair procedure. If no codes are present and all systems are functioning correctly, proceed with the following: A. Inspect the engine mounts for signs of deterioration or grounding. Repair or replace as necessary. B. Inspect all rotating components such as halfshafts, brake rotors, tires and wheels for any abnormal conditions that could contribute to low frequency vibrations. C. Road test the vehicle at normal operating temperatures while monitoring transmission performance using a DRB II or III. Use the RPM display screen, in the transmission diagnostic section, to display converter clutch function and throttle angle. EMCC shudder generally is encountered at 10 to 15 degrees throttle on smooth roads between 38 to 42 MPH depending on final drive ratio. The PRNDL readout on the DRB II or III can be either "3PL" or "4PL" during the shudder. To verify that the shudder is EMCC induced, the EMCC feature should be disengaged. This can be done by accelerating at medium/heavy throttle, or lightly depressing the brake pedal, or disengaging the throttle. If after doing any of these and the shudder disappears, go to the repair procedure. PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 180594 > Apr > 94 > TCC - Acceleration Shudder/DTC 38 Set > Page 4863 REPAIR PROCEDURE: This bulletin involves replacing the transmission front pump assembly and the transmission torque converter with one that has bonded converter clutch friction material. 1. Following the procedures outlined in the appropriate Service Manual, replace the torque converter and the transmission front pump assembly with the parts identified in the parts section of this bulletin. 2. Perform the transmission oil cooler and lines reverse flushing and flow check procedure as outlined in the appropriate Service Manual. 3. Before performing the torque converter clutch break in reset procedure verify that the repair has corrected the shudder condition. Drive the vehicle under the same conditions that caused the shudder. If the condition is corrected, go to step four. NOTE: SOME LIGHT SHUDDER MAY BE PRESENT BEFORE RESETTING THE EMCC BREAK-IN PROCEDURE. If severe shudder is still present, refer to the diagnostic section of this bulletin and re-evaluate the items listed. 4. Using the DRB II or III Scan Tool, perform the Torque Converter Clutch Break-in Procedure listed in the appropriate Service Manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-60-05-91 1993 - 1994 AA, AC, AG, AP, AS & 1992 - 1993 AY 6.1 Hrs. 1993 - 1994 LH 7.1 Hrs. 21-00-05-63 1993 - 1994 AS (Anti-Lock Brake System Equipped) 0.2 Hrs. 21-00-05-64 1993 - 1994 AS (All Wheel Drive Equipped) 1.2 Hrs. FAILURE CODE: 52 - Improperly Machined Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 4864 Torque Converter: Specifications 31TH Flex plate to torque converter bolts ......................................................................................................................................................... 75 Nm ( 55 ft-lbs ) 41TE Drive plate to torque converter bolts ....................................................................................................................................................... 75 Nm ( 55 ft-lbs ) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 4865 Torque Converter: Description and Operation The torque converter is similar in function and design to other Chrysler torque converters. The torque converter clutch engages or disengages the turbine assembly to the impeller housing. The application of the converter clutch is controlled electronically by the solenoid assembly and valve body. The torque converter transmits torque from the engine crankshaft to the input shaft of the transaxle. The torque converter clutch may engage (under the right conditions) in either 2nd, 3rd or 4th gears. The torque converter clutch engagement is normally very smooth and may even be undetectable by the driver. There are two types of torque converter engagement: partial and full engagement. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > A/T - 41TE/42LE Shudder During EMCC Shift Technical Service Bulletin # 21-05-97 Date: 970314 A/T - 41TE/42LE Shudder During EMCC Shift NO: 21-05-97 GROUP: Transmission DATE: Mar. 14, 1997 SUBJECT: 41TE/42LE Transaxle Shudder During an EMCC (Electronically Modulated Converter Clutch) Shift MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: 1989 TO 1995 MODELS SHOULD HAVE TSB 18-24-95 PERFORMED PRIOR TO PROCEEDING WITH THIS REPAIR PROCEDURE. SYMPTOM/CONDITION: Transaxle shudder during a 3rd gear to 3rd gear partial EMCC (Electronically Modulated Converter Clutch) engagement, 3rd gear partial EMCC to 4th gear partial EMCC engagement, or 4th gear to 4th gear EMCC engagement. Vehicle speed will be above 40 mph to obtain these shift points. This condition can be the result of worn out automatic transaxle fluid, using additives in the transaxle fluid, or from using the wrong type fluid (Dexron II, III, or Mercon) in the transaxle. NOTE: MOPAR ATF+2 TYPE 7176 IS THE ONLY RECOMMENDED FLUID FOR THESE TRANSAXLES. DIAGNOSIS: Bring the vehicle to normal operating temperatures. Drive the vehicle on a smooth road while accelerating through the gears with light throttle application. Pay particular attention during the EMCC shifts that take place between 3rd and 4th gears above 40 mph. If vehicle shudder is noticed during the shifts, perform the Repair Procedure. PARTS REQUIRED: 1 04864505 Filter, 41TE Transaxle 1 04796730 Filter, 42LE Transaxle AR(1) 06032780 0-Ring, Filter AR 04798233 Oil, ATF+2 Type 7176 (Qts) AR(1) 82300234 Sealant, RTV POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-55-01-96 1.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > A/T - 41TE/42LE Shudder During EMCC Shift > Page 4870 This repair involves changing the transaxle fluid and filter, driving the vehicle 10 miles and changing the transaxle fluid a second time. 1. Raise the vehicle on a hoist. 2. Clean the transaxle oil pan area and adjoining surfaces. 3. Loosen the transaxle oil pan and drain the fluid into a suitable container. 4. Remove the pan and clean all sealant form the pan and transaxle mating surfaces. Clean the inside of the pan and magnet. 5. Separate the filter and 0-ring from the valve body. Inspect the 0-ring for cuts or improper installation which can lead to delayed garage shifts. 6. Install a new filter p/n 04796730 (42LE) or p/n 04864505 (41TE). Replace the 0-ring p/n 06032780 as necessary. 7. Apply a 1/8 inch bead of Mopar RTV Sealant p/n 82300234 to the mounting flange of the transaxle oil pan. Apply RTV Sealant to the underside of the attaching bolts. Attach the oil pan to the transaxle and torque the bolts to 19 Nm (165 in. Lbs.). 8. Lower the vehicle and add 4 quarts of Mopar ATF +2 Type 7176 transaxle fluid p/n 04798233 through the transaxle fill tube. 9. Start the engine and allow it to idle for a minimum of one minute. With the parking brake applied, press your foot on the service brake and cycle the transaxle from park to all gear positions ending in neutral or park. 10. Check the transaxle fluid level and add an appropriate amount to bring the level to 3 mm (1/8 in.) below the ADD mark on the dipstick. 11. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range. 12. Drive the vehicle a minimum of 10 miles. 13. Repeat steps 1 through 4. 14. Separate the filter from the valve body to allow additional fluid to drain from the transaxle. Inspect the filter 0-ring for any damage and replace if necessary. 15. After the transaxle has stopped draining, re-install the filter and 0-ring. 16. Complete re-assembly and filling of the transaxle by following steps 7 through 11. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Torque Converter Clutch Solenoid: Component Locations Automatic Transmission Electrical Connections (4 Speed) Switch mounted in transaxle, (automatic only). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 4875 Torque Converter Clutch Solenoid: Connector Locations Electrical Connections, 3 Speed Automatic Automatic Transmission Electrical Connections (4 Speed) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Description and Operation > 3 Speed Transmission Torque Converter Clutch Solenoid: Description and Operation 3 Speed Transmission Transmission Switches (locations) PURPOSE The PCM applies and removes the ground from this solenoid to engage or disengage the lock-up torque converter. OPERATION The lock-up torque converter is only locked up when the transmission is in direct drive mode. If the PCM receives a signal from the throttle position sensor that an increase or decrease in throttle is needed (when the transmission gear selector is in direct drive), the PCM will disengage the part throttle solenoid causing the lock-up torque converter to be disengaged. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Description and Operation > 3 Speed Transmission > Page 4878 Torque Converter Clutch Solenoid: Description and Operation 4 Speed Overdrive Transmission Automatic Transmission Electrical Connections (4 Speed) PURPOSE The PCM applies and removes the ground from this solenoid to engage or disengage the lock-up torque converter. OPERATION The lock-up torque converter is only locked up when the transmission is in direct drive mode. If the PCM receives a signal from the throttle position sensor that an increase or decrease in throttle is needed (when the transmission gear selector is in direct drive), the PCM will disengage the part throttle solenoid causing the lock-up torque converter to be disengaged. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Transmission Control Relay Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Transmission Control Relay > Page 4883 Transmission Control System Relay: Locations Transmission (Safety Shut-Down) Relay Transmission Relay Location The Transmission Relay is located in LH side of engine compartment in the Power Distribution Center. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Transmission Control Relay > Page 4884 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 4885 Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Relay, A/T > Component Information > Locations > Component Locations Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Relay, A/T > Component Information > Locations > Component Locations > Page 4893 Back Up Lamp Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4902 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4903 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4904 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4910 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4911 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4916 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4917 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4918 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4924 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4925 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4928 Park Neutral Position Switch / PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4929 Transmission Position Switch/Sensor: Locations 4 Speed A/T Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 4932 Park / Neutral Position Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 4935 Transmission Position Switch/Sensor: Description and Operation Switch, Transmission Range The white Transmission Range Switch (formerly called PRNDL) is used as an input to the Transmission Control Module, on the 4 speed electronic automatic transaxle. Note: The Transmission Range Sensor is a different component from the Transmission Range Switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 4938 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 4939 Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations 41 TE/AE Transaxle Pressure And Cooler Ports Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 4951 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4956 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4957 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4958 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 4964 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4969 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4970 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4971 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4972 Input / Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector Input Speed Sensor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector > Page 4975 Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4976 Transmission Speed Sensor: Description and Operation Three pressure switches incorporated in an assembly with the solenoids identify solenoid application. Two speed sensors read input (torque converter turbine) and output (parking sprag) speeds. Position switch indicates manual shift lever position. Engine speed, throttle position, temperature, etc., are also observed. - Some of these signals are read directly from the engine control sensors; others are read from a multiplex circuit with the powertrain control module. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4977 Transmission Speed Sensor: Testing and Inspection INPUT (TURBINE) SPEED SENSOR INSPECTION 1. Disconnect the input speed sensor connector. 2. Measure the resistance between the input speed sensor side connector terminals 1 and 2. Standard value: 0.3k - 1.2k ohms 3. If the resistance is outside the standard value, replace the input speed sensor. OUTPUT SPEED SENSOR INSPECTION 1. Disconnect the output speed sensor connector. 2. Measure the resistance between the input speed sensor side connector terminals I and 2. Standard value: 0.3k - 1.2k ohms 3. If the resistance is outside the standard value, replace the output speed sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4978 Transmission Speed Sensor: Service and Repair CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Input (Turbine) Speed Sensor INPUT The input speed sensor is located to the left of the manual shift lever. CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Output Speed Sensor OUTPUT The output speed sensor is located to the right of the manual shift lever. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4990 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4991 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4992 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4998 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4999 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5000 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > Component Locations A604 (41TE) 4 Speed Transaxle Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > Component Locations > Page 5003 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Transaxle Solenoid Connector Transaxle Solenoid Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Transaxle Solenoid Connector > Page 5006 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information Valve Body: Description and Operation General Information The 41TE has a cast aluminum valve body that uses five or seven valves to control five transaxle clutches and the torque converter clutch. It also directs pressurized fluid for lubrication. The oil pump is the source of pressurized fluid for the valve body and solenoid assembly. The pump is a positive displacement, gear and crescent type pump. It is driven by the engine through the torque converter hub. The valve body has two major functions: - Control line pressure and TCC pressure - Direct fluid to the clutches, torque converter, lubrication system and the solenoids by means of the manual and switch valves Fluid for the pump is drawn through the transaxle filter, through the valve body housing and into the pump. The pump pressurizes the fluid and sends it back through the valve body to the regulator valve. The valve body uses five valves along with four solenoids in the solenoid assembly to provide control of the transaxle through all of its gear ranges. They perform all functions needed to operate the transaxle for each of its gear ranges. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 5009 Valve Body: Description and Operation Manual Valve The manual valve operates by mechanical shift linkage only. Its job is to send line pressure to the appropriate hydraulic circuits and solenoids. The valve has three operating ranges or positions. The valve shifts to the left position when OD, Drive or Low is selected. The valve shifts to the middle position in both Park and Neutral. The valve moves to the right position when Reverse is selected. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 5010 Valve Body: Description and Operation Regulator Valve The regulator valve has one-function: to regulate or control-hydraulic pressure in the transaxle. The pump supplies unregulated pressure to the regulator valve. The regulator valve controls, or limits, pump pressure. Regulated pressure is referred to as "line pressure." The regulator valve has a spring on one end that pushes the valve to the right. This closes a dump (vent) to lower pressure. Closing the dump will cause oil pressure to increase. Oil pressure on the opposite end of the valve pushes the valve to the left, opening the dump and lowering oil pressure. The result is spring tension working against oil pressure to keep or maintain the oil at specific pressures. Regulated.pressure varies depending on the gear range the transaxle is operating in. A system of sleeves and ports allows the regulator valve to work at one of three different predetermined pressure levels. The oil that is dumped by the regulator valve is directed back to the intake side of the oil pump. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 5011 Valve Body: Description and Operation Solenoid Switch Valve The solenoid switch valve controls the direction of line pressure from the LR/CC solenoid. When the valve is shifted to the right, it allows the low/reverse clutch to be pressurized. When it is shifted to the left, it directs line pressure to the TC and CC control valves to operate the TC clutch. The valve is shifted to the right in all positions except 2nd, 3rd and 4th gear. When the transaxle upshifts to 2nd gear, the valve moves to the left, which allows converter clutch engagement when needed. The valve must return to the right before a downshift to 1st gear can occur. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 5012 Valve Body: Description and Operation General Information The 41TE has a cast aluminum valve body that uses five or seven valves to control five transaxle clutches and the torque converter clutch. It also directs pressurized fluid for lubrication. The oil pump is the source of pressurized fluid for the valve body and solenoid assembly. The pump is a positive displacement, gear and crescent type pump. It is driven by the engine through the torque converter hub. The valve body has two major functions: - Control line pressure and TCC pressure - Direct fluid to the clutches, torque converter, lubrication system and the solenoids by means of the manual and switch valves Fluid for the pump is drawn through the transaxle filter, through the valve body housing and into the pump. The pump pressurizes the fluid and sends it back through the valve body to the regulator valve. The valve body uses five valves along with four solenoids in the solenoid assembly to provide control of the transaxle through all of its gear ranges. They perform all functions needed to operate the transaxle for each of its gear ranges. Manual Valve Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 5013 The manual valve operates by mechanical shift linkage only. Its job is to send line pressure to the appropriate hydraulic circuits and solenoids. The valve has three operating ranges or positions. The valve shifts to the left position when OD, Drive or Low is selected. The valve shifts to the middle position in both Park and Neutral. The valve moves to the right position when Reverse is selected. Regulator Valve The regulator valve has one-function: to regulate or control-hydraulic pressure in the transaxle. The pump supplies unregulated pressure to the regulator valve. The regulator valve controls, or limits, pump pressure. Regulated pressure is referred to as "line pressure." The regulator valve has a spring on one end that pushes the valve to the right. This closes a dump (vent) to lower pressure. Closing the dump will cause oil pressure to increase. Oil pressure on the opposite end of the valve pushes the valve to the left, opening the dump and lowering oil pressure. The result is spring tension working against oil pressure to keep or maintain the oil at specific pressures. Regulated.pressure varies depending on the gear range the transaxle is operating in. A system of sleeves and ports allows the regulator valve to work at one of three different predetermined pressure levels. The oil that is dumped by the regulator valve is directed back to the intake side of the oil pump. Solenoid Switch Valve Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 5014 The solenoid switch valve controls the direction of line pressure from the LR/CC solenoid. When the valve is shifted to the right, it allows the low/reverse clutch to be pressurized. When it is shifted to the left, it directs line pressure to the TC and CC control valves to operate the TC clutch. The valve is shifted to the right in all positions except 2nd, 3rd and 4th gear. When the transaxle upshifts to 2nd gear, the valve moves to the left, which allows converter clutch engagement when needed. The valve must return to the right before a downshift to 1st gear can occur. Torque Converter Clutch Control Valve Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 5015 The Torque Converter Clutch (TCC) control valve controls the back (ON) side of the torque converter clutch. When the TCM energizes the LR/CC solenoid to engage the converter clutch piston, the TCC control valve and torque converter control valves move to the left. The oil on the front (OFF) side of the converter clutch piston is vented to the sump. Line pressure enters the TCC control valve through the manual valve, and then passes through the TCC control valve and the torque converter control valve to the back (ON) side of the converter clutch piston. Line pressure forces the piston forward, which engages the torque converter clutch. This action effectively connects the torque converter turbine with the impeller. Line pressure also flows from the regulator valve, through the torque converter control valve, to the cooler and cooler bypass, for improved fluid and transaxle cooling. Torque Converter Control Valve Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 5016 The torque converter control valves main responsibility is to control. hydraulic pressure applied to the front (OFF) side of the converter clutch. Line pressure from the regulator valve is fed to the torque converter control valve, where it passes through the valve. The torque converter control valve reduces, or regulates, the pressure slightly. The torque converter control valve pressure is then directed to the converter clutch control valve and to the front side of the converter clutch piston. The pressure that is being fed to the front of the piston pushes the piston back. This disengages the converter clutch. The oil then passes around the outside of the piston, flowing out of the torque converter and back to the torque converter control valve. From the torque converter control valve, the oil flows to the transaxle oil cooler and cooler bypass valve. It returns to the transaxle as lube oil pressure. Beginning in 1996, the torque converter control valve was modified to delete the function of regulating the flow to the torque converter when the converter clutch is not applied. The valve switches the direction of fluid flow when the converter clutch is applied and vents the release side of the torque converter clutch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation Valve Body: Service and Repair Removal and Installation Removal Oil Pan Bolts Oil Pan Oil Filter Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5019 Valve Body Attaching Bolts NOTE: To ease installation of the valve body, turn the manual valve lever fully clockwise. Push Park Rollers From Guide Bracket Remove Valve Body Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5020 Valve Body Removed Installation To install valve body, reverse removal procedure. CAUTION: The valve body manual shaft pilot may distort and bind the manual valve if the valve body is mishandled or dropped. NOTE: To ease installation of the valve body, turn the manual valve lever fully clockwise. Guide park rod rollers into guide bracket, while shifting manual lever assembly out of the installation position. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5021 Valve Body: Service and Repair Solenoid Assembly Replacement REMOVAL Input Speed Sensor Removed Remove Sound Cover Remove Attaching Screws Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5022 Remove Solenoid Assembly INSTALLATION To install solenoid assembly, reverse removal procedure. Tighten screws to 12 Nm (105 inch lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5023 Valve Body: Service and Repair 41TE 4-Speed Transmission Range Sensor Screw Transmission Range Sensor Removed Manual Shaft And Rooster Comb Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5024 2-4 Accumulator Plate TRS, Manual Shaft, And 2-4 Accumulator Valve Body Screws Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5025 Valve Body And Transfer Plate Transfer Plate And Separator Plate Ball Check Location Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5026 Springs And Valves Location Remove Or Install Dual Retainer Plate TC Limit Valve And Low/Reverse Switch Valve Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection Bosch & Nippondenso Starters The clutch pedal switch is a normally open type switch. 1. Locate and disconnect clutch pedal switch connector. 2. Using a suitable continuity tester, check circuit through switch with pedal released, there should be no continuity. 3. With continuity tester still attached, push clutch pedal to floor, tester should show full continuity. 4. Tester should not show continuity until pedal is fully depressed, replace switch if it fails any test. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications Fluid - Differential: Specifications TYPE ................................................................................................................................................... ........................................................... 80W-90 GL-5 CAPACITY, Refill: All with longitudinal engine .......................................................................................................................................................... 0.9 Liters 2.0 Pints Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair Axle Shaft: Service and Repair REMOVAL 1. Remove cotter pin, locknut and spring washer from wheel hub. 2. Loosen hub nut with brakes applied. 3. Raise and support vehicle, then remove wheel and tire assembly. Fig. 18 Speedometer pinion removal 4. If removing right driveshaft, speedometer pinion must be removed prior to driveshaft removal. 5. Remove ball joint stud to steering knuckle clamp bolt, then separate ball joint stud from steering knuckle using a suitable pry bar. CAUTION: Use caution not to damage ball joint or CV joint boots. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 5040 6. Separate outer CV joint splined shaft from hub by holding CV housing while moving knuckle/hub assembly away. CAUTION: Do not use pry bar to separate hub from shaft or damage to outer wear sleeve on CV joint may occur. 7. Support driveshaft assembly at CV joint housing and remove by pulling outward on inner CV joint housing. Do not pull on shaft. 8. Remove driveshaft assembly from vehicle. INSTALLATION Caution: During any service procedures where knuckle and driveshaft are separated, clean seal and wear sleeve with suitable solvent, and apply a suitable lubricant to both components. Solvent must not touch the boot. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 5041 1. Hold inner joint assembly at housing while aligning and guiding inner joint spline into transaxle. 2. Push knuckle/hub assembly out and install outer CV joint shaft into hub. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 5042 3. Install knuckle assembly on ball joint stud, then clamp bolt. Tighten bolt to 70 ft lbs. Steering knuckle clamp bolt is prevailing torque type. Original, or equivalent bolt must be installed during assembly. 4. Install speedometer pinion, right driveshaft only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 5043 5. Fill transaxle with suitable transaxle fluid. 6. Install washer and hub nut, then tighten hub nut to 200 ft lbs. Install nut lock and cotter pin. 7. If inboard boot appears collapsed or deformed following installation, vent inner boot by inserting a round tipped, small diameter rod between boot and shaft. As venting occurs, boot will return to normal shape. 8. Install wheel and tire assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint Constant Velocity Joint: Service and Repair Inner CV Joint Disassembly Driveshaft assembly should be identified before starting service procedure. On some models when removing housing from tripod, it may be necessary to hold rollers in place on trunnion studs to prevent needles and rollers from falling out. 1. Remove boot clamps and pull back boot. Fig. 9 Tripod Removal From Housing 2. On models with S.S.G. driveshafts, pry wire ring tripod retainer from groove around top of housing using a suitable flathead screwdriver. Do not distort or damage retainer ring. 3. On all models, clamp shaft of CV joint housing in a vise. Use protective caps on jaws of vice to prevent damage to shaft. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint > Page 5048 Fig. 10 Tripod Removal From Housing 4. With interconnecting shaft on an angle to joint housing, gently pull on shaft until one of tripod bearings is free of plastic retaining collar. Gently pull on shaft until all rollers are free of housing. 5. On models with spring and cup, remove spring and cup from joint housing. Fig. 11 Outer Snap Ring Removal 6. On all models, remove outer snap ring from interconnecting shaft. 7. Remove tripod assembly from interconnecting shaft by tapping on body of tripod assembly with a suitable brass hammer. Do not hit outer bearing when removing assembly from interconnecting shaft. 8. If replacing boot, proceed as follows: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint > Page 5049 Fig. 12 Inner Tripod Retaining Snap Ring Removal a. On models with inner tripod snap ring, remove snap ring from interconnecting shaft. b. On all models, pull boot from interconnecting shaft. Inspection Remove grease from assembly and inspect bearing race, tripod components, spring cup, spring and spherical end of connecting shaft for excessive wear or damage. Inspect boot for pinholes, cracks or other damage. Assembly 1. If replacing boot, slide new boot into position over end of interconnecting shaft. 2. On models with single snap ring tripod retention, install new boot to interconnecting shaft, then the tripod assembly until it is past ring groove. Install new snap ring into interconnecting shaft. 3. On models with dual tripod retaining snap rings, install inner tripod snap ring to interconnecting shaft. 4. On all models, install tripod assembly onto interconnecting shaft, chamfer end down. If necessary, tap tripod assembly onto interconnecting shaft using a suitable brass hammer. Do not strike bearing assemblies with hammer. 5. Install outer tripod assembly retaining snap ring to interconnecting shaft. 6. Apply suitable CV joint grease into housing and boot. Fig. 13 Spring & Cup Installation 7. On models with internal spring and cup, place spring into housing spring pocket with spring cup attached to exposed end of spring. Place small amount of grease on concave surface of spring cup. 8. On all models, clamp stub shaft of housing in a suitable vice with protective caps on jaws. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint > Page 5050 9. On models with plastic retaining collar, while holding housing on an angle, insert each roller one at a time into retainer collar until all are seated and locked into housing. 10. On models with wire retaining ring, slip tripod into housing and install tripod wire retaining ring. 11. On models less plastic collar or wire ring, insert tripod into housing. 12. On all models, position boot over boot retaining groove in housing. Ensure boot is not dimpled or twisted, if necessary, use a suitable blunt tool to pry up edge of boot to allow air pressure to equalize. 13. Place new clamp into position on large end of boot, then using a suitable crimping tool, tighten clamp into place. 14. Refer to chart below for correct driveshaft length. To achieve an accurate measurement, slide small end of boot and outer housing onto interconnecting shaft. Trans driveshaft side dimension "A" type mm inch FWD GKN right 476-486 18.7-19.1 FWD GKN left 184-194 7.2-7.6 AWD GKN right 292-302 11.5-11.9 AWD GKN left 184-194 7.2-7.6 15. Install clamp, then using a suitable crimping tool, tighten clamp into place. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint > Page 5051 Constant Velocity Joint: Service and Repair Outer CV Joint Disassembly Driveshaft assembly should be identified before starting service procedure. Fig. 6 Driveshaft Components 1. Remove boot clamps, then pull back boot to gain access to joint. 2. Clean grease from joint. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint > Page 5052 3. Place driveshaft assembly in suitable vise with soft faces and support outer joint. Fig. 14 Outer CV Joint Removal From Shaft 4. On G.K.N. models, remove outer CV joint from shaft by tapping top of joint body with a suitable soft hammer. 5. On G.K.N. models, remove circlip from shaft groove and discard. 6. On S.S.G. units, proceed as follows: a. Mark position of damper weight, then loosen bolts. b. Slide damper weight and boot towards inner joint. Fig. 15 Circlip Retainer In Cross c. Using suitable circlip pliers, expand and hold circlip, then slide joint from shaft. If necessary tap top of joint body with a suitable soft hammer. 7. On all models, if boot is to be replaced, slide boot from interconnecting shaft. 8. If constant velocity joint is operating satisfactorily and grease does not appear contaminated, proceed to "Assembly" procedure. 9. If constant velocity joint is noisy or badly worn, replace entire unit. Repair kit will include boot, clamps, circlip and lubricant. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint > Page 5053 Fig. 16 Outer CV Joint Ball Removal 10. Remove surplus grease and mark relative position of inner cross, cage and housing with a dab of paint. 11. Hold joint vertically in a soft jawed vise. 12. Press downward on one side of inner race to tilt cage and remove ball from opposite side. If joint is tight, use a suitable hammer and brass drift to tap inner race. Do not strike cage. Repeat this step until all balls have been removed. A screwdriver may be used to pry balls loose. 13. Tilt cage assembly vertically and position two opposing, elongated cage windows in area between ball grooves. Fig. 17 Outer CV Joint Cage & Cross Assembly Removal 14. Remove cage and inner race assembly by pulling upward from housing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint > Page 5054 Fig. 18 Outer CV Joiont Cross Removal From Cage 15. Rotate inner cross 0.0° to cage and align a race spherical land with an elongated cage window. Raise land into cage window and remove inner race cross by swinging outward. Inspection 1. Check housing ball races for excessive wear. 2. Check splined shaft and nut threads for damage. 3. Inspect balls for pitting, cracks, scouring and wearing. Dulling of surface is normal. 4. Inspect cage for excessive wear on inner and outer spherical surfaces, heavy brinnelling of cage, and window cracks and chipping. 5. Inspect inner race (cross) for excessive wear or scoring of ball races. 6. If any defects are found, replace CV joint assembly as a unit. Polished areas in races (cross and housing) and cage spheres are normal and do not indicate a need for joint replacement unless they are suspected of causing noise and vibration. 7. Inspect boots for pinholes, cracks or other damage. Assembly 1. Position wear sleeve on joint housing, then tap sleeve onto housing using oil seal installer tool No. C-4698, or equivalent. 2. Lightly oil components, then align marks made during disassembly. Fig. 19 Inner CV Joint Cross Installation Into Cage Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint > Page 5055 3. Align an inner race (cross) land into cage window, then insert race into cage and pivot 90°. Fig. 20 Outer CV Joint Cage & Cross Assembly Installation Into Housing 4. Align opposing elongated cage windows with housing land and insert cage assembly into housing. Pivot cage 90° to complete installation. Fig. 21 Cage & Cross Assembled Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint > Page 5056 Fig. 22 Cage & Cross Installed In Housing When properly assembled, large counterbore in cross should be facing outward from joint on G.K.N. joint. Fig. 23 Cage & Cross Assembled On S.S.G. joint, internal clip in cross will be facing outward from housing. 5. Apply suitable lubricant to ball races between all sides of ball grooves. 6. Insert balls into raceway by tilting cage and inner race assembly. 7. Slide small end of boot over shaft, then place clamp over groove on boot. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Inner CV Joint > Page 5057 Fig. 24 Outer CV Joint Circlip Installation 8. On G.K.N. joint, insert new circlip in shaft groove. Do not over expand or twist circlip during assembly. 9. On S.S.G. unit, install reusable circlip. 10. On all models, position joint housing on shaft, then engage by tapping sharply with a suitable soft faced mallet. 11. Ensure snap ring is properly seated by attempting to pull joint from shaft. 12. Position boot over boot groove in housing, then install clamp. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments Fig. 3 Wheel bearing assembly 1. Raise and support rear of vehicle. 2. Tighten adjusting nut to specifications, while rotating wheel. 3. Stop wheel and loosen adjusting nut by 1/4 turn. 4. Tighten adjusting nut finger tight. Endplay should be .001-.003 inch. 5. Install castle lock with slots aligned with cotter pin hole. 6. Install cotter pin and grease cap. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front This hub and bearing assembly is being used on certain extended wheelbase Caravan, Voyager and Mini Ram Vans. This unit is serviced as a complete assembly, and is attached to the steering knuckle by four mounting screws that are removed from the rear of the knuckle assembly. Remove 1. Remove cotter pin, nut lock, and spring washer. 2. Loosen hub nut while the vehicle is on the floor with the brakes applied. The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut. 3. Raise vehicle. 4. Remove hub nut, washer, and wheel and tire assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5063 5. Disconnect tie rod end from steering arm with Tool C-3894-A. 6. Remove clamp bolt securing ball joint stud into steering knuckle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5064 7. Remove caliper guide pins and separate caliper assembly from braking disc. SUPPORT CALIPER WITH WIRE HOOK AND NOT BY HYDRAULIC HOSE. Remove braking disc. 8. Separate ball joint stud from knuckle assembly. Pull knuckle assembly out and away from driveshaft. NOTE: Care must be taken not to separate the Inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint, driveshaft must be supported. 9. Remove the four hub and bearing assembly mounting screws from rear of steering knuckle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5065 10. Remove hub and bearing assembly. Replacement of the grease seal is recommended whenever this service is performed. Installation 1. Install new hub and bearing assembly and tighten screws in a criss-cross pattern to 45 ft.lbs. (65 Nm.). CAUTION: Knuckle and bearing mounting surfaces must be smooth and completely free of foreign material or nicks. 2. Position new seal in recess and assemble installer Tool C-4698 tool is provided with a handle and dual purpose drive head for installing seal into knuckle and (head reversed) for installing wear sleeve into C/V joint housing). 3. Assemble tool and install seal. CAUTION: During any service procedures where knuckle and driveshaft are separated, thoroughly clean seal and wear sleeve and relubricate BOTH components. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5066 4. Lubricate the full circumference of the seal (and wear sleeve) with MOPAR Multi-Purpose Lubricant or equivalent. 5. Install driveshaft through hub, then install steering knuckle assembly on lower control arm ball joint stud. 6. Install original (or equivalent) ball joint to knuckle clamp bolt, torque to 95 Nm (70 ft.lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5067 7. Install tie rod end into steering arm, tighten nut to 47 Nm (35 ft.lbs.) torque and install cotter key. 8. Install braking disc. 9. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment on knuckle assembly. Install guide pins and tighten to 25-35 Nm (18-26 ft.lbs.). When installing guide pins, use extreme caution not to cross the threads. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5068 10. Install washer and hub nut after cleaning foreign matter from threads. 11. With brakes applied, tighten nut to 180 ft.lbs. (244 Nm). 12. Install spring washer, nut lock, and new cotter pin. Wrap cotter pin prongs tightly around nut lock. 13. Install wheel and tire assembly. Tighten wheel nuts to 85 ft.lbs. (115 Nm). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5069 Wheel Bearing: Service and Repair Rear REMOVAL AND INSTALLATION 1. Remove the rear tire and wheel assembly. 2. Remove grease cap, cotter pin, nut lock, nut, thrust washer and outer wheel bearing. 3. Carefully slide hub or drum from spindle. Do not drag inner bearing or grease seal over stub axle (thread, bearing, and oil seal may be damaged.) Using an appropriate tool remove the grease seal and inner bearing from the drum or hub. Discard grease seal, a new seal should be used when reinstalling the inner bearing. 4. Thoroughly clean all old grease from the outer and inner bearings, bearing cups and hub cavity. To clean bearings, soak them in an appropriate cleaning solvent. Strike the flat surface of the bearing inner race against a hardwood block several times, to loosen grease. Immerse the bearings in solvent between blows to jar loose and wash old particles of hardened grease from bearings. Repeat this operation until bearings are clean. Bearings can be dried using compressed air but do not spin the bearings. After cleaning, oil the bearings with engine oil. Insert the bearing into its appropriate cup, apply pressure to the bearing while rotating it to test them for pitting and roughness. Replace all worn or defective bearings. If bearing shows signs of pitting or roughness they should be replaced. Bearings must be replaced as a set, both the cup and the bearing need to be replaced at the same time. If bearings are suitable for further use, remove engine oil from bearings using appropriate solvent and dry bearings. Repack the bearings using a Multi-Purpose NLGI. Grade 2 EP Grease such as Mopar® or equivalent, and place them in a clean covered container until ready for installation. If a bearing packer is not available, hand pack grease into all cavities between bearing cage and rollers. 5. If bearings and cups are to be replaced, remove cups from the drum or hub using a brass drift or suitable remover. 6. Replace bearing cups with appropriate installing tool. 7. Install inner bearing in grease coated hub and bearing cup, and install new grease seals using the appropriate seal installer. 8. Coat outer hub cavity and cup with grease. 9. Before installing hub or drum assembly, inspect stub axle and seal surface for burrs or roughness, and smooth out all rough surfaces. 10. Coat the stub axle with Multi-Purpose NLGI, Grade 2 EP grease or equivalent. 11. Carefully slide the hub of drum assembly onto the stub axle. Do not drag seal or inner bearing over the threaded area of the stub axle. 12. Install outer bearing, thrust washer and nut. 13. Tighten the wheel bearing adjusting nut to 27 to 34 Nm (240 to 300 in.lbs.) while rotating hub or drum assembly. This seats the bearings. 14. Back off adjusting nut 1/4 turn (90°) then tighten adjusting nut only finger tight. 15. Position the nut lock over the bearing adjusting nut with one pair of slots in line with the cotter pin hole in the stub axle. Install cotter pin. 16. Install the grease caps and the wheel and tire assemblies. Tighten wheel stud nuts to 115 Nm (85 ft. lbs.) on all models. Reinstall wheel covers if so equipped. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Front Wheel Hub: Service and Repair Front This hub and bearing assembly is being used on certain extended wheelbase Caravan, Voyager and Mini Ram Vans. This unit is serviced as a complete assembly, and is attached to the steering knuckle by four mounting screws that are removed from the rear of the knuckle assembly. Remove 1. Remove cotter pin, nut lock, and spring washer. 2. Loosen hub nut while the vehicle is on the floor with the brakes applied. The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut. 3. Raise vehicle. 4. Remove hub nut, washer, and wheel and tire assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Front > Page 5074 5. Disconnect tie rod end from steering arm with Tool C-3894-A. 6. Remove clamp bolt securing ball joint stud into steering knuckle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Front > Page 5075 7. Remove caliper guide pins and separate caliper assembly from braking disc. SUPPORT CALIPER WITH WIRE HOOK AND NOT BY HYDRAULIC HOSE. Remove braking disc. 8. Separate ball joint stud from knuckle assembly. Pull knuckle assembly out and away from driveshaft. NOTE: Care must be taken not to separate the Inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint, driveshaft must be supported. 9. Remove the four hub and bearing assembly mounting screws from rear of steering knuckle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Front > Page 5076 10. Remove hub and bearing assembly. Replacement of the grease seal is recommended whenever this service is performed. Installation 1. Install new hub and bearing assembly and tighten screws in a criss-cross pattern to 45 ft.lbs. (65 Nm.). CAUTION: Knuckle and bearing mounting surfaces must be smooth and completely free of foreign material or nicks. 2. Position new seal in recess and assemble installer Tool C-4698 tool is provided with a handle and dual purpose drive head for installing seal into knuckle and (head reversed) for installing wear sleeve into C/V joint housing). 3. Assemble tool and install seal. CAUTION: During any service procedures where knuckle and driveshaft are separated, thoroughly clean seal and wear sleeve and relubricate BOTH components. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Front > Page 5077 4. Lubricate the full circumference of the seal (and wear sleeve) with MOPAR Multi-Purpose Lubricant or equivalent. 5. Install driveshaft through hub, then install steering knuckle assembly on lower control arm ball joint stud. 6. Install original (or equivalent) ball joint to knuckle clamp bolt, torque to 95 Nm (70 ft.lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Front > Page 5078 7. Install tie rod end into steering arm, tighten nut to 47 Nm (35 ft.lbs.) torque and install cotter key. 8. Install braking disc. 9. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment on knuckle assembly. Install guide pins and tighten to 25-35 Nm (18-26 ft.lbs.). When installing guide pins, use extreme caution not to cross the threads. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Front > Page 5079 10. Install washer and hub nut after cleaning foreign matter from threads. 11. With brakes applied, tighten nut to 180 ft.lbs. (244 Nm). 12. Install spring washer, nut lock, and new cotter pin. Wrap cotter pin prongs tightly around nut lock. 13. Install wheel and tire assembly. Tighten wheel nuts to 85 ft.lbs. (115 Nm). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Front > Page 5080 Wheel Hub: Service and Repair Rear REMOVAL AND INSTALLATION 1. Remove the rear tire and wheel assembly. 2. Remove grease cap, cotter pin, nut lock, nut, thrust washer and outer wheel bearing. 3. Carefully slide hub or drum from spindle. Do not drag inner bearing or grease seal over stub axle (thread, bearing, and oil seal may be damaged.) Using an appropriate tool remove the grease seal and inner bearing from the drum or hub. Discard grease seal, a new seal should be used when reinstalling the inner bearing. 4. Thoroughly clean all old grease from the outer and inner bearings, bearing cups and hub cavity. To clean bearings, soak them in an appropriate cleaning solvent. Strike the flat surface of the bearing inner race against a hardwood block several times, to loosen grease. Immerse the bearings in solvent between blows to jar loose and wash old particles of hardened grease from bearings. Repeat this operation until bearings are clean. Bearings can be dried using compressed air but do not spin the bearings. After cleaning, oil the bearings with engine oil. Insert the bearing into its appropriate cup, apply pressure to the bearing while rotating it to test them for pitting and roughness. Replace all worn or defective bearings. If bearing shows signs of pitting or roughness they should be replaced. Bearings must be replaced as a set, both the cup and the bearing need to be replaced at the same time. If bearings are suitable for further use, remove engine oil from bearings using appropriate solvent and dry bearings. Repack the bearings using a Multi-Purpose NLGI. Grade 2 EP Grease such as Mopar® or equivalent, and place them in a clean covered container until ready for installation. If a bearing packer is not available, hand pack grease into all cavities between bearing cage and rollers. 5. If bearings and cups are to be replaced, remove cups from the drum or hub using a brass drift or suitable remover. 6. Replace bearing cups with appropriate installing tool. 7. Install inner bearing in grease coated hub and bearing cup, and install new grease seals using the appropriate seal installer. 8. Coat outer hub cavity and cup with grease. 9. Before installing hub or drum assembly, inspect stub axle and seal surface for burrs or roughness, and smooth out all rough surfaces. 10. Coat the stub axle with Multi-Purpose NLGI, Grade 2 EP grease or equivalent. 11. Carefully slide the hub of drum assembly onto the stub axle. Do not drag seal or inner bearing over the threaded area of the stub axle. 12. Install outer bearing, thrust washer and nut. 13. Tighten the wheel bearing adjusting nut to 27 to 34 Nm (240 to 300 in.lbs.) while rotating hub or drum assembly. This seats the bearings. 14. Back off adjusting nut 1/4 turn (90°) then tighten adjusting nut only finger tight. 15. Position the nut lock over the bearing adjusting nut with one pair of slots in line with the cotter pin hole in the stub axle. Install cotter pin. 16. Install the grease caps and the wheel and tire assemblies. Tighten wheel stud nuts to 115 Nm (85 ft. lbs.) on all models. Reinstall wheel covers if so equipped. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications 31TH Flex plate to crankshaft bolts ............................................................................................................... .................................................... 95 Nm ( 70 ft-lbs ) 41TE Drive plate to crankshft bolts ............................................................................................................... ................................................... 95 Nm ( 70 ft-lbs ) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 212493 > Sep > 93 > M/T - Vent Oil Leak Case: Customer Interest M/T - Vent Oil Leak NO.: 21-24-93 GROUP: Transmission DATE: Sep. 3, 1993 SUBJECT: Oil Leak At Transaxle Vent MODELS: 1990 - 1993 (AG) Daytona 1990 - 1994 (AA) Spirit/Acclaim (AJ) LeBaron Coupe/LeBaron Convertible (AP) Shadow/Shadow Convertible/Sundance (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH MANUAL TRANSAXLE MODELS A-523, A-543, OR A-568. SYMPTOM/CONDITION: Transaxle oil leak on or around selector shaft cover and/or other surrounding surfaces, including the rear end cover and differential bearing retainer. Oil found to be leaking out of vent cap on crossover lever. NOTE: THIS REPAIR SHOULD BE PREFORMED ON ALL VEHICLES WITH A VENT LEAK. CUSTOMER VEHICLES THAT ARE IN THE DEALERSHIP FOR ANY OTHER REASON SHOULD ALSO BE INSPECTED FOR THIS LEAK CONDITION. PARTS REQUIRED: 1 Vent Adapter 4762499 1 Vent 4505557 REPAIR PROCEDURE: This bulletin involves installing a remote vent assembly in place of the existing lock pin. Also included is a new linkage adjusting procedure if needed for future transaxle service. 1. Clean any excess oil from surrounding surfaces. 2. Remove, lock pin located on transaxle selector shaft cover (Figure 1). Discard lock pin. 3. Install vent adapter (P/N 4762499) in selector shaft cover where lock pin was removed. Tighten to 40 in.lbs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 212493 > Sep > 93 > M/T - Vent Oil Leak > Page 5093 4. Install vent (P/N 4505557) into vent adaptor (P/N 4762499) and tighten to 35 in. lbs. NOTE: IF FOR ANY REASON THE SHIFT LINKAGE REQUIRES ADJUSTMENT, THE FOLLOWING PROCEDURE IS PROVIDED AND DOES NOT REQUIRE THE USE OF A LOCK PIN. 1. Gain access to the transaxle crossover cable adjusting screw located at the floor shifter in the vehicle interior as outlined in the appropriate service manual. 2. Loosen the adjusting screw to allow the crossover cable adjustment fitting to slide freely (Figure 2). 3. Shift the transaxle into 4th gear then into 3rd gear and then back into 4th gear. Leave gearshift lever in the 4th gear position and tighten crossover cable adjusting screw to 70 in.lbs. CAUTION: DO NOT LEAN ON OR APPLY A LOAD TO THE SHIFT LEVER WHEN TIGHTENING THE ADJUSTING SCREW. 4. Reinstall all hardware removed in Step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 21-35-36-93 0.3 Hrs. FAILURE CODE: 71 - Oil Leak Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 212493 > Sep > 93 > M/T - Vent Oil Leak Case: All Technical Service Bulletins M/T - Vent Oil Leak NO.: 21-24-93 GROUP: Transmission DATE: Sep. 3, 1993 SUBJECT: Oil Leak At Transaxle Vent MODELS: 1990 - 1993 (AG) Daytona 1990 - 1994 (AA) Spirit/Acclaim (AJ) LeBaron Coupe/LeBaron Convertible (AP) Shadow/Shadow Convertible/Sundance (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH MANUAL TRANSAXLE MODELS A-523, A-543, OR A-568. SYMPTOM/CONDITION: Transaxle oil leak on or around selector shaft cover and/or other surrounding surfaces, including the rear end cover and differential bearing retainer. Oil found to be leaking out of vent cap on crossover lever. NOTE: THIS REPAIR SHOULD BE PREFORMED ON ALL VEHICLES WITH A VENT LEAK. CUSTOMER VEHICLES THAT ARE IN THE DEALERSHIP FOR ANY OTHER REASON SHOULD ALSO BE INSPECTED FOR THIS LEAK CONDITION. PARTS REQUIRED: 1 Vent Adapter 4762499 1 Vent 4505557 REPAIR PROCEDURE: This bulletin involves installing a remote vent assembly in place of the existing lock pin. Also included is a new linkage adjusting procedure if needed for future transaxle service. 1. Clean any excess oil from surrounding surfaces. 2. Remove, lock pin located on transaxle selector shaft cover (Figure 1). Discard lock pin. 3. Install vent adapter (P/N 4762499) in selector shaft cover where lock pin was removed. Tighten to 40 in.lbs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 212493 > Sep > 93 > M/T - Vent Oil Leak > Page 5099 4. Install vent (P/N 4505557) into vent adaptor (P/N 4762499) and tighten to 35 in. lbs. NOTE: IF FOR ANY REASON THE SHIFT LINKAGE REQUIRES ADJUSTMENT, THE FOLLOWING PROCEDURE IS PROVIDED AND DOES NOT REQUIRE THE USE OF A LOCK PIN. 1. Gain access to the transaxle crossover cable adjusting screw located at the floor shifter in the vehicle interior as outlined in the appropriate service manual. 2. Loosen the adjusting screw to allow the crossover cable adjustment fitting to slide freely (Figure 2). 3. Shift the transaxle into 4th gear then into 3rd gear and then back into 4th gear. Leave gearshift lever in the 4th gear position and tighten crossover cable adjusting screw to 70 in.lbs. CAUTION: DO NOT LEAN ON OR APPLY A LOAD TO THE SHIFT LEVER WHEN TIGHTENING THE ADJUSTING SCREW. 4. Reinstall all hardware removed in Step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 21-35-36-93 0.3 Hrs. FAILURE CODE: 71 - Oil Leak Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > Customer Interest for Shifter M/T: > 210994 > Jun > 94 > M/T - Shifter Squeak When Shifting Shifter M/T: Customer Interest M/T - Shifter Squeak When Shifting NO: 21-09-94 GROUP: Transmission EFFECTIVE DATE: Jun. 10 1994 SUBJECT: Shifter Squeak - Manual Transmission MODELS: 1990 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1994 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION. DISCUSSION: A squeak noise may occur when shifting into or out of a gear. The noise is coming from where the select shift cable attaches to the gear shift lever. DO NOT ATTEMPT TO LUBRICATE THE SHIFTER PIN TO ELIMINATE THE SQUEAK NOISE. PETROLEUM BASE LUBRICANTS WILL REDUCE THE DURABILITY OF THE CABLE ISOLATOR. If a subject vehicle exhibits this condition, replace the shifter assembly using the procedure outlined in the appropriate service manual. The correct part numbers for the shifter assembly are listed below: 4670218 AP and AA Vehicles 4670219 AS Vehicles 4670220 PL Vehicles POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter M/T: > 210994 > Jun > 94 > M/T Shifter Squeak When Shifting Shifter M/T: All Technical Service Bulletins M/T - Shifter Squeak When Shifting NO: 21-09-94 GROUP: Transmission EFFECTIVE DATE: Jun. 10 1994 SUBJECT: Shifter Squeak - Manual Transmission MODELS: 1990 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1994 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION. DISCUSSION: A squeak noise may occur when shifting into or out of a gear. The noise is coming from where the select shift cable attaches to the gear shift lever. DO NOT ATTEMPT TO LUBRICATE THE SHIFTER PIN TO ELIMINATE THE SQUEAK NOISE. PETROLEUM BASE LUBRICANTS WILL REDUCE THE DURABILITY OF THE CABLE ISOLATOR. If a subject vehicle exhibits this condition, replace the shifter assembly using the procedure outlined in the appropriate service manual. The correct part numbers for the shifter assembly are listed below: 4670218 AP and AA Vehicles 4670219 AS Vehicles 4670220 PL Vehicles POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 210994 > Jun > 94 > M/T - Shifter Squeak When Shifting Shift Cable: Customer Interest M/T - Shifter Squeak When Shifting NO: 21-09-94 GROUP: Transmission EFFECTIVE DATE: Jun. 10 1994 SUBJECT: Shifter Squeak - Manual Transmission MODELS: 1990 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1994 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION. DISCUSSION: A squeak noise may occur when shifting into or out of a gear. The noise is coming from where the select shift cable attaches to the gear shift lever. DO NOT ATTEMPT TO LUBRICATE THE SHIFTER PIN TO ELIMINATE THE SQUEAK NOISE. PETROLEUM BASE LUBRICANTS WILL REDUCE THE DURABILITY OF THE CABLE ISOLATOR. If a subject vehicle exhibits this condition, replace the shifter assembly using the procedure outlined in the appropriate service manual. The correct part numbers for the shifter assembly are listed below: 4670218 AP and AA Vehicles 4670219 AS Vehicles 4670220 PL Vehicles POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 210994 > Jun > 94 > M/T - Shifter Squeak When Shifting Shift Cable: All Technical Service Bulletins M/T - Shifter Squeak When Shifting NO: 21-09-94 GROUP: Transmission EFFECTIVE DATE: Jun. 10 1994 SUBJECT: Shifter Squeak - Manual Transmission MODELS: 1990 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1994 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION. DISCUSSION: A squeak noise may occur when shifting into or out of a gear. The noise is coming from where the select shift cable attaches to the gear shift lever. DO NOT ATTEMPT TO LUBRICATE THE SHIFTER PIN TO ELIMINATE THE SQUEAK NOISE. PETROLEUM BASE LUBRICANTS WILL REDUCE THE DURABILITY OF THE CABLE ISOLATOR. If a subject vehicle exhibits this condition, replace the shifter assembly using the procedure outlined in the appropriate service manual. The correct part numbers for the shifter assembly are listed below: 4670218 AP and AA Vehicles 4670219 AS Vehicles 4670220 PL Vehicles POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5137 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5138 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5139 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5140 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5141 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5142 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Control Module: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 5147 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 5148 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts Control Module: Customer Interest A/T - Harsh Gear Engagement/Upshifts/Downshifts NO.: 21-36-93 GROUP: Transmission DATE: Dec. 10, 1993 SUBJECT: Improved Transmission Shift Schedule MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH 09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION. SYMPTOM/CONDITION: Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1 kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary Neutral/Drive garage shifts. Park to Reverse noise (grunt). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4686478 Transmission Control Module AR 4467721 Transmission Fluid - ATF Plus (7176) REPAIR PROCEDURE: This repair involves the replacement of the transmission control module with a module that incorporates revised software, changing the transmission fluid, setting the pinion factor, and transaxle quick learn. 1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is currently installed on the vehicle. This is accomplished by choosing the TSB option under Adjustments. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS INSPECTED AT THE RETURN CENTER. 2. Replace the transmission control module with the new module, following the procedures outlined in the appropriate service manual. 3. Change the transmission fluid following the procedure outlined in the service manual. NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER. 4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and then place gear selector in Neutral. 5. Using the procedures listed in the service manual complete the following: a. Quick Learn Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 5153 b. Electronic Pinion Factor Procedure 6. Drive the vehicle at least 10 miles. 7. Change the transmission fluid again following the procedure outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-06-90 2.1 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5159 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5160 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5161 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5162 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5163 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5164 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Control Module: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 5169 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 5170 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts Control Module: All Technical Service Bulletins A/T - Harsh Gear Engagement/Upshifts/Downshifts NO.: 21-36-93 GROUP: Transmission DATE: Dec. 10, 1993 SUBJECT: Improved Transmission Shift Schedule MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH 09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION. SYMPTOM/CONDITION: Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1 kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary Neutral/Drive garage shifts. Park to Reverse noise (grunt). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4686478 Transmission Control Module AR 4467721 Transmission Fluid - ATF Plus (7176) REPAIR PROCEDURE: This repair involves the replacement of the transmission control module with a module that incorporates revised software, changing the transmission fluid, setting the pinion factor, and transaxle quick learn. 1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is currently installed on the vehicle. This is accomplished by choosing the TSB option under Adjustments. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS INSPECTED AT THE RETURN CENTER. 2. Replace the transmission control module with the new module, following the procedures outlined in the appropriate service manual. 3. Change the transmission fluid following the procedure outlined in the service manual. NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER. 4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and then place gear selector in Neutral. 5. Using the procedures listed in the service manual complete the following: a. Quick Learn Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 5175 b. Electronic Pinion Factor Procedure 6. Drive the vehicle at least 10 miles. 7. Change the transmission fluid again following the procedure outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-06-90 2.1 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor Axle Ratio Values Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values NO.: 08-39-93 Rev. A GROUP: Electrical DATE: Sep. 17, 1993 SUBJECT: 41TE Pinion Factor Axle Ratio Values NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** MODELS: **1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue ** DISCUSSION: When installing a replacement TCM (Transmission Control Module), it is necessary to set the pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the speedometer indicates correctly. One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the correct axle ratios for the various applications: YEAR ENGINE SIZE RATIO 1993 3.8L 3.19 3.0L and 3.3L 3.62 1994 3.8L 3.45 3.0L and 3.3L 3.62 POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor Axle Ratio Values Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values NO.: 08-39-93 Rev. A GROUP: Electrical DATE: Sep. 17, 1993 SUBJECT: 41TE Pinion Factor Axle Ratio Values NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** MODELS: **1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue ** DISCUSSION: When installing a replacement TCM (Transmission Control Module), it is necessary to set the pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the speedometer indicates correctly. One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the correct axle ratios for the various applications: YEAR ENGINE SIZE RATIO 1993 3.8L 3.19 3.0L and 3.3L 3.62 1994 3.8L 3.45 3.0L and 3.3L 3.62 POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module Transmission Control Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 5187 Power Control Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 5188 Control Module: Locations Power Distribution Center Power Distribution Center Fuse Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5191 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5192 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5193 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5194 Control Module: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5195 Control Module: Connector Views Part 1 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5196 Part 2 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5197 Part 3 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5198 Part 4 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5199 Part 5 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5200 Part 6 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5201 Part 7 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5202 Part 8 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5203 Part 9 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5204 Part 10 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5205 Part 11 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5206 Transmission Control Schematic Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information Control Module: Description and Operation General Information Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5209 The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transaxle. The TCM receives information from several inputs, and selects the operational mode of the transaxle. Some of the inputs are used only by the TCM, while others are shared with other control modules on the CCD Bus. Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for operating conditions. This is to determine the desired gear range the transaxle must be operated in. The actual shift points within each shift schedule have been predetermined for the best transaxle operation, and are stored in the TCM's ROM memory. Once a TCM is installed during service, the following procedures must be performed: - Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the vehicle - Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes and final drive ratios on 1993 and newer vehicles The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the TCM learning process. The vehicle must still be driven and shifted several times in each gear range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool. NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module display on the DRB III scan tool Emission regulations require the use of two labels after a flash update: - Emission Modification Label - Emission Part Number Modification Label The following provides information on TCM identification and flash programming application: 1989 - 92 Original controllers were non-finned and are non-flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit 1993 - 95 Original controllers were finned with four heat sinks and are flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This TSB also lists the 1990 vehicles that require a wiring modification to pin 49. 1996 Original controllers were finned with seven heat sinks and are flashable - Replacement controllers have fins with seven heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the common DLC Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5210 Control Module: Description and Operation Electronic Transmission Controller Operation LOCATION The EATX control module is located under the hood, in a potted, die cast aluminum housing with a sealed, 60-way connector. ADAPTIVE CONTROLS These controls function by reading the input and output speeds over 140 times a second and responding to each new reading. - This provides the precise friction element control needed to make smooth clutch-to-clutch shifts for all gear changes. As with most automatic transaxles, all shifts involve releasing one element and applying a different element. - In simplified terms, the upshift logic allows the releasing element to slip backwards slightly, to ensure that it does not have excess capacity; the apply element is filled until it begins to make the speed change to the higher gear; its apply pressure is then controlled to maintain the desired rate of speed change until the shift is complete. The key to providing excellent shift quality is precision; EXAMPLE As mentioned, the release element for upshifts is allowed to slip backwards slightly; the amount of that slip is typically less than a total of 20 degrees. LEARNING To achieve that precision, the EATX control module learns the characteristics of the particular transaxle that it is controlling. - It learns the release rate of the releasing element and the apply time of the applying element. - It also learns the rate at which the apply element builds pressure sufficient to begin making the speed change. - This method achieves more precision than would be possible with exacting tolerances. It can also adapt to any changes that occur with age or environment, for example, altitude, temperature, engine output, etc. KICKDOWN SHIFTING For kickdown shifts, the control logic allows the releasing element to slip and then controls the rate at which the input (and engine) accelerate; when the lower gear speed is achieved, the releasing element reapplies to maintain that speed until the apply element is filled. This provides quick response since the engine begins to accelerate immediately and a smooth torque exchange since the release element can control the rate of torque increase. This control can make any power train feel more responsive without increasing harshness. SUMMARY Adaptive controls respond to input speed changes They compensate for changes in engine or friction element torque and provide good, consistent shift quality for the life of the transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information Control Module: Service and Repair General Information Do not interchange Transmission Control Modules with previous-year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: - Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information > Page 5213 Control Module: Service and Repair Replacement NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner. REMOVAL 1. Disconnect the battery negative cable. 2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect the 60 way connector on Transmission Control Module. 3. Remove Transmission Control Module mounting screws and lift module from vehicle. INSTALLATION To install, reverse removal procedures. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Transmission Control Relay Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Transmission Control Relay > Page 5218 Transmission Control System Relay: Locations Transmission (Safety Shut-Down) Relay Transmission Relay Location The Transmission Relay is located in LH side of engine compartment in the Power Distribution Center. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Transmission Control Relay > Page 5219 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5220 Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations > Page 5225 Back Up Lamp Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Override Switch <--> [Overdrive Switch, A/T] > Component Information > Locations Overdrive Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Override Switch <--> [Overdrive Switch, A/T] > Component Information > Locations > Page 5231 Overdrive Off Switch (8 - Way) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5243 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5244 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5245 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 5251 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 5252 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5257 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5258 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5259 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 5265 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 5266 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 5269 Park Neutral Position Switch / PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 5270 Transmission Position Switch/Sensor: Locations 4 Speed A/T Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 5273 Park / Neutral Position Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 5276 Transmission Position Switch/Sensor: Description and Operation Switch, Transmission Range The white Transmission Range Switch (formerly called PRNDL) is used as an input to the Transmission Control Module, on the 4 speed electronic automatic transaxle. Note: The Transmission Range Sensor is a different component from the Transmission Range Switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 5279 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 5280 Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 5289 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5294 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5295 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5296 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 5302 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5307 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5308 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5309 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 5310 Input / Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector Input Speed Sensor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector > Page 5313 Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5314 Transmission Speed Sensor: Description and Operation Three pressure switches incorporated in an assembly with the solenoids identify solenoid application. Two speed sensors read input (torque converter turbine) and output (parking sprag) speeds. Position switch indicates manual shift lever position. Engine speed, throttle position, temperature, etc., are also observed. - Some of these signals are read directly from the engine control sensors; others are read from a multiplex circuit with the powertrain control module. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5315 Transmission Speed Sensor: Testing and Inspection INPUT (TURBINE) SPEED SENSOR INSPECTION 1. Disconnect the input speed sensor connector. 2. Measure the resistance between the input speed sensor side connector terminals 1 and 2. Standard value: 0.3k - 1.2k ohms 3. If the resistance is outside the standard value, replace the input speed sensor. OUTPUT SPEED SENSOR INSPECTION 1. Disconnect the output speed sensor connector. 2. Measure the resistance between the input speed sensor side connector terminals I and 2. Standard value: 0.3k - 1.2k ohms 3. If the resistance is outside the standard value, replace the output speed sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5316 Transmission Speed Sensor: Service and Repair CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Input (Turbine) Speed Sensor INPUT The input speed sensor is located to the left of the manual shift lever. CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Output Speed Sensor OUTPUT The output speed sensor is located to the right of the manual shift lever. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Diagrams > Diagram Information and Instructions Transfer Case: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5324 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5325 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5326 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5327 Transfer Case: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5328 Transfer Case: Electrical Diagrams Transmission Control & AWD System (Part 1 Of 5) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5329 Transmission Control & AWD System (Part 2 Of 5) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5330 Transmission Control & AWD System (Part 3 Of 5) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5331 Transmission Control & AWD System (Part 4 Of 5) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5332 Transmission Control & AWD System (Part 5 Of 5) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop Shift Solenoid: Customer Interest A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 5344 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop Shift Solenoid: All Technical Service Bulletins A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Solenoid: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 5350 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 5351 Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Technical Service Bulletins > Page 5352 Transmission Solenoid Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Torque Converter Clutch Solenoid: Component Locations Automatic Transmission Electrical Connections (4 Speed) Switch mounted in transaxle, (automatic only). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 5357 Torque Converter Clutch Solenoid: Connector Locations Electrical Connections, 3 Speed Automatic Automatic Transmission Electrical Connections (4 Speed) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Description and Operation > 3 Speed Transmission Torque Converter Clutch Solenoid: Description and Operation 3 Speed Transmission Transmission Switches (locations) PURPOSE The PCM applies and removes the ground from this solenoid to engage or disengage the lock-up torque converter. OPERATION The lock-up torque converter is only locked up when the transmission is in direct drive mode. If the PCM receives a signal from the throttle position sensor that an increase or decrease in throttle is needed (when the transmission gear selector is in direct drive), the PCM will disengage the part throttle solenoid causing the lock-up torque converter to be disengaged. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Description and Operation > 3 Speed Transmission > Page 5360 Torque Converter Clutch Solenoid: Description and Operation 4 Speed Overdrive Transmission Automatic Transmission Electrical Connections (4 Speed) PURPOSE The PCM applies and removes the ground from this solenoid to engage or disengage the lock-up torque converter. OPERATION The lock-up torque converter is only locked up when the transmission is in direct drive mode. If the PCM receives a signal from the throttle position sensor that an increase or decrease in throttle is needed (when the transmission gear selector is in direct drive), the PCM will disengage the part throttle solenoid causing the lock-up torque converter to be disengaged. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5371 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5372 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5373 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5374 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5375 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5376 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Control Module: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 5381 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 5382 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts Control Module: Customer Interest A/T - Harsh Gear Engagement/Upshifts/Downshifts NO.: 21-36-93 GROUP: Transmission DATE: Dec. 10, 1993 SUBJECT: Improved Transmission Shift Schedule MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH 09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION. SYMPTOM/CONDITION: Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1 kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary Neutral/Drive garage shifts. Park to Reverse noise (grunt). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4686478 Transmission Control Module AR 4467721 Transmission Fluid - ATF Plus (7176) REPAIR PROCEDURE: This repair involves the replacement of the transmission control module with a module that incorporates revised software, changing the transmission fluid, setting the pinion factor, and transaxle quick learn. 1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is currently installed on the vehicle. This is accomplished by choosing the TSB option under Adjustments. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS INSPECTED AT THE RETURN CENTER. 2. Replace the transmission control module with the new module, following the procedures outlined in the appropriate service manual. 3. Change the transmission fluid following the procedure outlined in the service manual. NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER. 4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and then place gear selector in Neutral. 5. Using the procedures listed in the service manual complete the following: a. Quick Learn Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 5387 b. Electronic Pinion Factor Procedure 6. Drive the vehicle at least 10 miles. 7. Change the transmission fluid again following the procedure outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-06-90 2.1 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality Technical Service Bulletin # 182495 Date: 950623 A/T - Poor Shift Quality NO: 18-24-95 GROUP: Veh. Performance DATE: Jun. 23, 1995 SUBJECT: Improved Transmission Shift Quality THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-27-94 REV. A, DATED JAN. 30, 1995 WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS REVISION ADDS MODELS AND A PART NUMBER. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1989 - 1995 (AA) Acclaim/Spirit/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1993** - 1994 (AP) Sundance/Shadow/Shadow Convertible 1990 - 1991 (AQ) Chrysler TC **1989** - 1995 (AS) Caravan/Voyager/Town & Country 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) **1995 (FJ) Sebring/Avenger/Talon** 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE TRANSAXLE. SYMPTOM/CONDITION: 1992 AC. & AY VEHICLES BUILT AFTER FEB. 15, 1992 (MDH 02-15-XX). **1995 FJ VEHICLES** AND ALL OTHER 1993-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24, 1994 (MDH 10-24-XX) ARE VEHICLES EQUIPPED WITH AN ELECTRONICALLY MODULATED CONVERTOR CLUTCH (EMCC). Vehicles that operate at speeds where EMCC usage is engaged (vehicle speeds between 34 - 41 MPH), may experience early deterioration of the transmission fluid (15,000 - 30,000 miles), exhibit a pronounced shudder during EMCC operation, harsh upshifts/downshifts, and/or harsh torque converter clutch engagements. Performing REPAIR PROCEDURE # 2, which includes updates to the Transmission Control Module (TCM) calibration and eliminates EMCC, will resolve these symptom/conditions. However, if an overheat condition is identified by the PCM or TCM, EMCC operation will be temporarily enabled. **ALL 1995 FJ VEHICLES** AND ALL OTHER 1989-1995 SUBJECT VEHICLES BUILT BEFORE OCT. 24. 1994 (MDH 10-24-XX). The TCM calibration used in the 1995 model year 41TE and 42LE TCM is being made available for all vehicles dating back to the 1989 model year. The shift quality improvements and default issues that will be corrected by the new TCM calibration are: 1. COASTDOWN TIP-IN BUMP: Vehicle is decelerated almost to a stop (less than 8 MPH), then the driver tips back into the throttle to accelerate, a noticeable bump may be felt. 2. COASTDOWN SHIFT HARSHNESS: Harsh coastdown shifts on some 4-3, 3-2 and 2-1 downshifts. 3. 1995 LH WITH 42LE TRANSAXLE - SLUGGISHNESS/LACK OF RESPONSE: On some early 1995 LH vehicles built prior to Oct. 24, 1994, a perceived lack of power or transmission responsiveness may be encountered under normal operating conditions. The transmission may not release the converter clutch as desired with increased throttle. This occurs in 4th gear from 35 MPH to 50 MPH. 4. 1989-1994 WITH 41TE & 42LE TRANSAXLES: Harsh shifts and/or vehicle shudder during 3-2 or 2-1 kickdowns at speeds less than 25 MPH. 5. 1993 WITH 41TE TRANSAXLE: Harsh 3-4 upshifts may occur, especially at highway speeds, while using the speed control. 6. 1989-1994 WITH 41TE TRANSAXLE - HARSH/DELAYED GARAGE SHIFTS: Delay is less than 2 seconds and the shift is harsh after the brief delay. NOTE: Delays greater than 2 seconds are caused by transmission hardware malfunction, i.e., valve body, pump, failed lip seals or Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5393 malfunctioning PRNDL or neutral start switch. 7. 1989-1994 WITH 41TE & 42LE TRANSAXLES- POOR SHIFT QUALITY AFTER A BATTERY DISCONNECT: All transmission learned values are reset to the factory default values if battery power is lost to the TCM. The new 1995 calibration will now retain all learned values in memory after battery disconnect. However. if a transmission is rebuilt or a new transmission or TCM is installed. the Quick Learn procedure must be performed to calibrate Clutch Volume Indexes (CVI) on 1993 and later vehicles (1992 and prior vehicle cannot be Quick Learned). NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND THE TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS PROCEDURE WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. 8. EARLY 1993 WITH 41TE & 42LE TRANSAXLE - INTERMITTENT SPEED CONTROL DROP OUT: The new service calibration change corrects this condition (this condition was also covered in Technical Service Bulletin 08-09-93 dated Mar. 12, 1993). 9. 1989-1993 WITH 41TE & 42LE TRANSAXLES - New fault code 35 (failure to achieve pump prime) has been added for improved diagnostic capability, and fault codes 21, 22 and 24 are de-sensitized to reduce erroneous limp-in conditions. Code 21 (OD Pressure Switch Circuit) Can be set in error on vehicles with a misadjusted shift cable or if the transaxle is shifted slowly from the OD position to the N position. This typically happens if the operator has a tendency to rest his hand on the shift lever, or overshoots the OD gate while manually shifting from L or 3 to OD. The new software detects this maneuver and shifts the transaxle into Neutral rather than setting code a 21 fault and the subsequent limp-in conditions. Code 22 and 24 (2-4 and L-R Pressure Switch Circuits) In low ambient temperatures (below 32° F or 0° C) some 1989 and 1990 model year vehicles may set this fault in error. Condensation can form and freeze in the PRNDL and/or neutral start switch and cause a delay on garage shifts. The new software prevents this fault code from being set in error and the transaxle going into the limp-in mode. Code 24 (Low Reverse Pressure Switch Circuit) Can get set in error on vehicles where pump prime problems exist. The new fault code 35 (failure to achieve pump prime) has been added and does not trigger a limp-in condition. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: LABOR OPERATION NO: 21-19-01-91 Module, Transmission Control - Reprogram (Includes Road Test).................................. ..........................................................................................................................0.7 Hrs. FAILURE CODE: FM - Flash Module LABOR OPERATION NO: 21-19-01-90 Module, Transmission Control - Replace (Includes Road Te st).......................................................................................................................................................... ..0.8 Hrs. FAILURE CODE: P8 - New Part RELATED OPERATIONS: 21-19-01-50 Fluid Replace Procedure..................................................................................................................................1.0 Hrs. 21-19-01-51 Pinion Factor............................................................................................................ .......................................0.2 Hrs. 21-19-01-52 Quick Learn................................................................. ....................................................................................0.1 Hrs. 21-19-01-53 Cavity 49 Modification....................................................................................................................................0.1 Hrs. Diagnosis DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. Inspect the transmission fluid for the correct level and red color. If no DTC's are present, all systems are functioning correctly, transaxle fluid is the normal red color and EMCC shudder is NOT a symptom but the transaxle does have any other symptom(s) listed above, perform REPAIR PROCEDURE NO. 1. If the transaxle fluid is discolored and/or exhibits the EMCC shudder, perform REPAIR PROCEDURE NO. 2 beginning on page 9. EQUIPMENT/PARTS REQUIRED FOR FLASHABLE TCM'S: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5394 1 CH5500 Flash Programming Kit 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7025 DIN Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 PARTS REQUIRED IF TCM REPLACEMENT IS NECESSARY: PART NO. TRANS. CONTROL MODULE AND MODEL APPLICATION AR 4686606 1993 - 1995 AA, AC, AG, AJ, AP, AS, ES, & AY AR 4796121 1989 - 1991 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796122 1990 - 1991 AC, AS, & AY with 3.3L & 3.8L Engine AR 4796123 1992 AA, AC, AG, AJ, & AS with 3.0L Engine AR 4796124 1992 AC, AS, ES, & AY with 3.3L & 3.SL Engine **AR 5269726 1995 FJ** AR 46061 OS 1995 JA with 2.5L Engine AR 4797708 1993 - 1995 LH AR 4504048 Package, Oil Filter 41TE AR 4796730 Package, Oil Filter 42LE AR 4467721 Fluid, Mopar Automatic Transmission - Type 7176 NOTE: WHEN FLASHING TO OR INSTALLING THE FOLLOWING TCM P/N's: 4796121, 4796122, 4796123, and 4796124 When flashing to or installing these TCM's, it is necessary to ensure no wire is connected at CAVITY 49 of the TCM wiring harness connector. If the wire is left connected, and the vehicle is driven at speeds fast enough for the transmission to be in 4th gear/Overdrive (OD), when the brake pedal is pushed, the transmission will shift into 3rd gear or if the transmission was already in 3rd gear it will shift into OD. If the brake pedal is pushed again, the transmission will have OD enabled/disabled (whether or not an actual shift takes place depends on vehicle speed) and will change between enabled/disabled OD each time the brake pedal is pushed. In addition to the normal TCM installation procedure, perform the following steps: A. Remove the cover from the wiring harness connector at the TCM. B. Locate CAVITY 49 of the TCM harness connector. C. Cut the wire going to CAVITY 49 of the TCM wiring harness connector so there is enough room at each of the cut ends of the wire to install a piece of shrink tubing, P/N 4778570. D. Slide a piece of shrink tubing over each cut end of the wire so the end of the wire is at the midpoint of the shrink tubing. Use an electric heat gun to shrink the tubing and seal the wire ends. E. Install the TCM wiring harness connector cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5395 Repair Procedure No. 1 REPAIR PROCEDURE NO. 1 This procedure involves either flashing the TOM with new calibrations or replacing the TCM if it cannot be flashed and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Examine the TCM for cooling fins and use a mirror to check the part number on the bottom of the TCM. If the vehicle is equipped with a TCM WITHOUT cooling fins on it or is one of the part numbers listed below the TCM CANNOT be flashed, go to step 10 under Control Modules that CANNOT be flashed. NOTE: THE MOPAR DIAGNOSTIC SYSTEM (MDS) IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 16 OR HIGHER INSTALLED. 2. Connecting the MDS and DRB III to the vehicle (Refer to illustration). A) With the ignition off, disconnect the vehicle 60 way connector from the TOM on the vehicle. B) Connect the controller programming harness (CH2500) from the Flash Programming Kit (CH5500) to the TOM on the vehicle. C) Connect the Flash Programming Adapter (CH1500) to the controller programming harness (CH2500) D) Connect the DRB III to the Flash Programming Adapter (CH1500) with DRB III DIN cable (CH7025). E) Connect the MDS to the DRB III. F) Power the DRB III and Adapter by connecting the battery leads to the vehicle battery. 3. Use the arrow keys on the DRB III and from the MAIN MENU Screen select MDS DIAGNOSTICS. 4. Use the arrow keys on the MDS and select DIAGNOSTIC MENU from the MDS screen, then press NEXT MENU. 5. Use the arrow keys on the MDS and select CONTROLLER PROGRAMMING, then press NEXT MENU. 6. Use the arrow keys on the MDS and select INFORMATION BY VIN, then press NEXT MENU. 7. Enter the VIN and press NEXT MENU. 8. The MDS will display the PROGRAMMABLE CONTROLLER UPDATE INFORMATION screen. Use the up/down arrow keys to scroll until the PRESS F8 TO VIEW TSB # line displays 18-27-94. Press F2 to begin the programming and follow the instructions on the MDS screen. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5396 If the controller on the vehicle has already been flashed, the MDS screen will state THIS CONTROLLER HAS ALREADY BEEN PROGRAMMED WITH THE LATEST SOFTWARE AVAILABLE. Follow instructions on the MDS screen to exit. 9. After programming is complete, disconnect the MDS and DRB III, then go to step 14. VEHICLES WITH TRANSAXLE CONTROL MODULES THAT CANNOT BE FLASHED 10. On 1993 - 1995 vehicles, program this Technical Service Bulletin No. (18-27-94) into the TCM that is currently installed on the vehicle (the Technical Service Bulletin No. cannot be programmed into 1992 and prior vehicles). This is accomplished by: A) Using a stand-alone DRB III (with release 16) on 1994 - 1995 vehicles: 1) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select STAND-ALONE DRB III. 3) Select 94-95 DIAGNOSTICS. 4) Select TRANSMISSION. 5) Select MISCELLANEOUS. 6) Select TSB and follow the instructions on the DRB III screen. B) Using a stand-alone DRB II (use super cartridge Version 7.0 or Version 8.0 depending on the individual vehicle) on 1993 - 1994 vehicles: 1) Connect the DRB II to the diagnostic connector at the bottom of the instrument panel near the steering column. 2) Select SYSTEM 3) Select TRANSMISSION. 4) Select ADJUSTMENTS. 5) Select TSB and follow the instructions on the DRB II screen. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE TCM IS INSPECTED AT THE CHRYSLER RETURN CENTER. 11. Replace the TCM with a revised TOM as specified in the Parts Required section of this TSB. Loosen the TOM 60-way connector screw and disconnect the 60-way connector from the TCM. Remove the TCM mounting screws and the TCM from the vehicle. Reverse the removal procedure to install the revised TCM. 12. Using the MDS and DRB III perform the Electronic Pinion Factor procedure on 1993 and later vehicles with 41TE transaxles when the TOM is replaced (not required on vehicles with 42LE transaxles, 1992 and prior models or if the TCM was flashed). A) Connect the DRB III to the diagnostic connector at the bottom of the instrument panel near the steering column and the MDS. B) From the DIAGNOSTIC MAIN MENU press NEXT MENU 2 times. C) Select EATX DIAGNOSTICS. D) Select EATX STATE DISPLAY and press F2. E) Select ADJUSTMENTS and press F2. F) Select PINION FACTOR and press F2. G) Follow the instructions on the MDS screen. NOTE: BEFORE PERFORMING THE QUICK LEARN PROCEDURE, THE TRANSMISSION MUST BE SHIFTED INTO OVERDRIVE (OD) WITH THE ENGINE RUNNING AND TRANSMISSION FLUID SET TO THE CORRECT LEVEL. THIS WILL PURGE THE AIR IN THE CLUTCH CIRCUITS TO PREVENT ERRONEOUS CLUTCH VOLUME VALUES WHICH COULD CAUSE POOR INITIAL SHIFT QUALITY. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5397 13. Using the MDS and DRB III perform the Quick Learn procedure, required whenever a transaxle or TCM is replaced on 1993 and later vehicles (Quick Learn cannot be performed on 1992 and prior vehicles). A) Start the vehicle, place the shift lever in OD, move the vehicle at least five feet and then place shift lever in Neutral. Apply the parking brake and let the engine idle. B) From the ADJUSTMENTS screen on MDS select QUICK LEARN and press F2. C) Follow the instructions on the MDS screen. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY FEDERAL LAW. 14. Type the necessary information on the Authorized Modification Label and attach the label near the Vehicle Emission Control Information (VECI) Label. 15. Type the necessary information on the "Authorized Software Update Label" and attach it to the TCM and cover label with a clear plastic sticker. Repair Procedure No. 2 REPAIR PROCEDURE NO. 2: This procedure involves either flashing the TCM with new calibrations or replacing the TCM if it can not be flashed, changing the transmission fluid, driving the vehicle 10 miles and changing the transmission fluid again and on 1993 and later models, setting the Pinion Factor and performing the Quick Learn procedure. 1. Perform steps 1-12 (as applicable) of REPAIR PROCEDURE NO. 1. 2. Disconnect the DRB III and MDS from the vehicle. 3. Change the transmission fluid using following the procedure: A) Raise the vehicle with an appropriate hoist. B) Clean the transaxle oil pan and mating area thoroughly. C) Remove the transaxle oil pan. Remove all sealant from the transaxle oil pan and mating area. Clean the inside of the oil pan and magnet. D) Check the transaxle oil filter engagement and O-ring condition. Cut or poorly installed 0-rings also may cause delayed garage shifts. E) Separate the transaxle oil filter and O-ring from the valve body and discard. F) Install the new oil filter specified in the Parts Required section of this TSB. G) Apply an 1/8 in. bead of Mopar RTV sealant, P/N 4318025, on the mounting flange of the transaxle oil pan. Apply Mopar RTV sealant to the underside of the attaching bolts. Torque the attaching bolts to 19 Nm (165 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 182495 > Jun > 95 > A/T - Poor Shift Quality > Page 5398 NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID TYPE 7176 (PIN 4467721). USE OF DEXTRON IIE OR DEXTRON III MAY CAUSE CLUTCH SHUDDER. H) Pour 4 quarts Mopar Automatic Transmission Fluid Type 7176 through the fill tube. I) Start the engine and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either Park or Neutral. J) Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. K) Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. 4. Drive the vehicle at least 10 miles. 5. Repeat step 3A - 3C of REPAIR PROCEDURE NO. 2. 6. Separate the transaxle oil filter and O-ring from the valve body and drain the fluid from it. This also allows for additional fluid to drain from the transmission. 7. After the transmission fluid has stopped draining, be sure the O-ring is not damaged, then reinstall the transaxle oil filter and O-ring to the valve body. 8. Repeat steps 3G - 3K of REPAIR PROCEDURE NO. 2. NOTE: THE FOLLOWING STEP IS REQUIRED BY FEDERAL LAW. 9. Perform steps 14 and 15 of REPAIR PROCEDURE NO. 1. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Control Module: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 5403 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 5404 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts Control Module: All Technical Service Bulletins A/T - Harsh Gear Engagement/Upshifts/Downshifts NO.: 21-36-93 GROUP: Transmission DATE: Dec. 10, 1993 SUBJECT: Improved Transmission Shift Schedule MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan C/V Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO ALL 1993 VEHICLES AND 1994 BUILT PRIOR TO MDH 09-30-XX EQUIPPED WITH THE 41TE TRANSMISSION. SYMPTOM/CONDITION: Harsh engagement with tip-in during low speed 2/1 coastdown shifts. Low speed harsh 2/1 kickdown shifts. Harsh 3/2 and 4/3 coastdown shifts. Harsh 3/4 upshifts. Harsh stationary Neutral/Drive garage shifts. Park to Reverse noise (grunt). DIAGNOSIS: Using the Mopar Diagnostic System or the Scan Tool (DRB II) with appropriate diagnostic procedure manual, verify that all engine systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4686478 Transmission Control Module AR 4467721 Transmission Fluid - ATF Plus (7176) REPAIR PROCEDURE: This repair involves the replacement of the transmission control module with a module that incorporates revised software, changing the transmission fluid, setting the pinion factor, and transaxle quick learn. 1. Using a DRBII, program this Technical Service Bulletin Number (21-36-93) into the TCM that is currently installed on the vehicle. This is accomplished by choosing the TSB option under Adjustments. NOTE: THIS STEP WILL BE ELECTRONICALLY VERIFIED WHEN THE MODULE IS INSPECTED AT THE RETURN CENTER. 2. Replace the transmission control module with the new module, following the procedures outlined in the appropriate service manual. 3. Change the transmission fluid following the procedure outlined in the service manual. NOTE: USE ONLY MOPAR ATF PLUS TRANSMISSION FLUID (AUTOMATIC TRANSMISSION FLUID TYPE 7176). USE OF DEXTRON IIE MAY CAUSE CLUTCH SHUDDER. 4. Start the vehicle and with the gear selector in Overdrive, move the vehicle at least five feet and then place gear selector in Neutral. 5. Using the procedures listed in the service manual complete the following: a. Quick Learn Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 213693 > Dec > 93 > A/T - Harsh Gear Engagement/Upshifts/Downshifts > Page 5409 b. Electronic Pinion Factor Procedure 6. Drive the vehicle at least 10 miles. 7. Change the transmission fluid again following the procedure outlined in the service manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Labor Operation No. 08-19-06-90 2.1 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor Axle Ratio Values Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values NO.: 08-39-93 Rev. A GROUP: Electrical DATE: Sep. 17, 1993 SUBJECT: 41TE Pinion Factor Axle Ratio Values NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** MODELS: **1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue ** DISCUSSION: When installing a replacement TCM (Transmission Control Module), it is necessary to set the pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the speedometer indicates correctly. One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the correct axle ratios for the various applications: YEAR ENGINE SIZE RATIO 1993 3.8L 3.19 3.0L and 3.3L 3.62 1994 3.8L 3.45 3.0L and 3.3L 3.62 POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 083993A > Sep > 93 > A/T - (41TE) Pinion Factor Axle Ratio Values Control Module: All Technical Service Bulletins A/T - (41TE) Pinion Factor Axle Ratio Values NO.: 08-39-93 Rev. A GROUP: Electrical DATE: Sep. 17, 1993 SUBJECT: 41TE Pinion Factor Axle Ratio Values NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-39-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** MODELS: **1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1993 (AY) Imperial/New Yorker Fifth Avenue ** DISCUSSION: When installing a replacement TCM (Transmission Control Module), it is necessary to set the pinion factor using the procedure listed in the appropriate Service Manual or Powertrain Diagnostic Procedures Manual and the DRBII (Scan Tool) or MDS (Mopar Diagnostic System) so that the speedometer indicates correctly. One of the steps in setting the pinion factor is selecting the proper axle ratio. Listed below are the correct axle ratios for the various applications: YEAR ENGINE SIZE RATIO 1993 3.8L 3.19 3.0L and 3.3L 3.62 1994 3.8L 3.45 3.0L and 3.3L 3.62 POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module Transmission Control Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 5421 Power Control Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 5422 Control Module: Locations Power Distribution Center Power Distribution Center Fuse Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5425 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5426 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5427 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5428 Control Module: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5429 Control Module: Connector Views Part 1 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5430 Part 2 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5431 Part 3 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5432 Part 4 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5433 Part 5 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5434 Part 6 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5435 Part 7 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5436 Part 8 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5437 Part 9 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5438 Part 10 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5439 Part 11 Of 11 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5440 Transmission Control Schematic Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information Control Module: Description and Operation General Information Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5443 The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transaxle. The TCM receives information from several inputs, and selects the operational mode of the transaxle. Some of the inputs are used only by the TCM, while others are shared with other control modules on the CCD Bus. Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for operating conditions. This is to determine the desired gear range the transaxle must be operated in. The actual shift points within each shift schedule have been predetermined for the best transaxle operation, and are stored in the TCM's ROM memory. Once a TCM is installed during service, the following procedures must be performed: - Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the vehicle - Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes and final drive ratios on 1993 and newer vehicles The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the TCM learning process. The vehicle must still be driven and shifted several times in each gear range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool. NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module display on the DRB III scan tool Emission regulations require the use of two labels after a flash update: - Emission Modification Label - Emission Part Number Modification Label The following provides information on TCM identification and flash programming application: 1989 - 92 Original controllers were non-finned and are non-flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit 1993 - 95 Original controllers were finned with four heat sinks and are flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This TSB also lists the 1990 vehicles that require a wiring modification to pin 49. 1996 Original controllers were finned with seven heat sinks and are flashable - Replacement controllers have fins with seven heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the common DLC Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5444 Control Module: Description and Operation Electronic Transmission Controller Operation LOCATION The EATX control module is located under the hood, in a potted, die cast aluminum housing with a sealed, 60-way connector. ADAPTIVE CONTROLS These controls function by reading the input and output speeds over 140 times a second and responding to each new reading. - This provides the precise friction element control needed to make smooth clutch-to-clutch shifts for all gear changes. As with most automatic transaxles, all shifts involve releasing one element and applying a different element. - In simplified terms, the upshift logic allows the releasing element to slip backwards slightly, to ensure that it does not have excess capacity; the apply element is filled until it begins to make the speed change to the higher gear; its apply pressure is then controlled to maintain the desired rate of speed change until the shift is complete. The key to providing excellent shift quality is precision; EXAMPLE As mentioned, the release element for upshifts is allowed to slip backwards slightly; the amount of that slip is typically less than a total of 20 degrees. LEARNING To achieve that precision, the EATX control module learns the characteristics of the particular transaxle that it is controlling. - It learns the release rate of the releasing element and the apply time of the applying element. - It also learns the rate at which the apply element builds pressure sufficient to begin making the speed change. - This method achieves more precision than would be possible with exacting tolerances. It can also adapt to any changes that occur with age or environment, for example, altitude, temperature, engine output, etc. KICKDOWN SHIFTING For kickdown shifts, the control logic allows the releasing element to slip and then controls the rate at which the input (and engine) accelerate; when the lower gear speed is achieved, the releasing element reapplies to maintain that speed until the apply element is filled. This provides quick response since the engine begins to accelerate immediately and a smooth torque exchange since the release element can control the rate of torque increase. This control can make any power train feel more responsive without increasing harshness. SUMMARY Adaptive controls respond to input speed changes They compensate for changes in engine or friction element torque and provide good, consistent shift quality for the life of the transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information Control Module: Service and Repair General Information Do not interchange Transmission Control Modules with previous-year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: - Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information > Page 5447 Control Module: Service and Repair Replacement NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner. REMOVAL 1. Disconnect the battery negative cable. 2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect the 60 way connector on Transmission Control Module. 3. Remove Transmission Control Module mounting screws and lift module from vehicle. INSTALLATION To install, reverse removal procedures. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Transmission Control Relay Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Transmission Control Relay > Page 5452 Transmission Control System Relay: Locations Transmission (Safety Shut-Down) Relay Transmission Relay Location The Transmission Relay is located in LH side of engine compartment in the Power Distribution Center. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Transmission Control Relay > Page 5453 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5454 Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations Back Up Lamp Relay / Transmission Control Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Position Relay, A/T > Component Information > Locations > Component Locations > Page 5459 Back Up Lamp Relay Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Override Switch <--> [Overdrive Switch, A/T] > Component Information > Locations Overdrive Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Override Switch <--> [Overdrive Switch, A/T] > Component Information > Locations > Page 5465 Overdrive Off Switch (8 - Way) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5477 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5478 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5479 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 5485 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 5486 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5491 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5492 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5493 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 5499 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 5500 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 5503 Park Neutral Position Switch / PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 5504 Transmission Position Switch/Sensor: Locations 4 Speed A/T Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch PRNDL Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > PRNDL Switch > Page 5507 Park / Neutral Position Switch Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 5510 Transmission Position Switch/Sensor: Description and Operation Switch, Transmission Range The white Transmission Range Switch (formerly called PRNDL) is used as an input to the Transmission Control Module, on the 4 speed electronic automatic transaxle. Note: The Transmission Range Sensor is a different component from the Transmission Range Switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range Transmission Position Switch/Sensor: Service and Repair Sensor, Transmission Range NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 5513 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Sensor, Transmission Range > Page 5514 Transmission Position Switch/Sensor: Service and Repair 4 Speed A/T Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control > Page 5523 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5528 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5529 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5530 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 5536 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 5541 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 5542 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 5543 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 5544 Input / Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector Input Speed Sensor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector > Page 5547 Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5548 Transmission Speed Sensor: Description and Operation Three pressure switches incorporated in an assembly with the solenoids identify solenoid application. Two speed sensors read input (torque converter turbine) and output (parking sprag) speeds. Position switch indicates manual shift lever position. Engine speed, throttle position, temperature, etc., are also observed. - Some of these signals are read directly from the engine control sensors; others are read from a multiplex circuit with the powertrain control module. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5549 Transmission Speed Sensor: Testing and Inspection INPUT (TURBINE) SPEED SENSOR INSPECTION 1. Disconnect the input speed sensor connector. 2. Measure the resistance between the input speed sensor side connector terminals 1 and 2. Standard value: 0.3k - 1.2k ohms 3. If the resistance is outside the standard value, replace the input speed sensor. OUTPUT SPEED SENSOR INSPECTION 1. Disconnect the output speed sensor connector. 2. Measure the resistance between the input speed sensor side connector terminals I and 2. Standard value: 0.3k - 1.2k ohms 3. If the resistance is outside the standard value, replace the output speed sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5550 Transmission Speed Sensor: Service and Repair CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Input (Turbine) Speed Sensor INPUT The input speed sensor is located to the left of the manual shift lever. CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Output Speed Sensor OUTPUT The output speed sensor is located to the right of the manual shift lever. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Technical Service Bulletins > Customer Interest for ABS Light: > 052294 > Dec > 94 > ABS Warning Light ON Continuously ABS Light: Customer Interest ABS - Warning Light ON Continuously NO: 05-22-94 GROUP: Brakes EFFECTIVE DATE: Dec. 2, 1994 SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor Connector MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) SYMPTOM/CONDITION: Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles brake system will perform as a non-ABS equipped vehicle normally would during this condition. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair as necessary. If an ABS wheel speed sensor DTC is discovered: 1. Disconnect the 2 way connector of the suspect wheel speed sensor. 2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body harness connector. There should be resistance/interference felt between the male and female terminals. 3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic Procedures for further diagnostics. 4. If no resistance/interference is felt at one or both terminals, perform the repair procedure. PARTS REQUIRED: 1 4797997 Kit, Terminal Repair Kit Consists Of: 1 4625196 Terminal, Male 1 Connector/Wire Assembly 2 4778570 Tube, Heat Shrink REPAIR PROCEDURE: This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread female terminals. 1. Cut off the suspect body harness connector and discard. 2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and the new connector/wire assembly. 3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and spread the strands of the wire. 4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands together with the strands prepared in step 3 and twist together. 5. Solder the wires together with ROSIN core solder. 6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 7. Repeat steps 3 - 6 for the other wires. 8. Connect the body harness to the wheel speed sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Technical Service Bulletins > Customer Interest for ABS Light: > 052294 > Dec > 94 > ABS Warning Light ON Continuously > Page 5564 9. Test drive the vehicle and verify proper operation of the ABS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-18-97 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Technical Service Bulletins > All Technical Service Bulletins for ABS Light: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously ABS Light: All Technical Service Bulletins ABS - Warning Light ON Continuously NO: 05-22-94 GROUP: Brakes EFFECTIVE DATE: Dec. 2, 1994 SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor Connector MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) SYMPTOM/CONDITION: Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles brake system will perform as a non-ABS equipped vehicle normally would during this condition. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair as necessary. If an ABS wheel speed sensor DTC is discovered: 1. Disconnect the 2 way connector of the suspect wheel speed sensor. 2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body harness connector. There should be resistance/interference felt between the male and female terminals. 3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic Procedures for further diagnostics. 4. If no resistance/interference is felt at one or both terminals, perform the repair procedure. PARTS REQUIRED: 1 4797997 Kit, Terminal Repair Kit Consists Of: 1 4625196 Terminal, Male 1 Connector/Wire Assembly 2 4778570 Tube, Heat Shrink REPAIR PROCEDURE: This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread female terminals. 1. Cut off the suspect body harness connector and discard. 2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and the new connector/wire assembly. 3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and spread the strands of the wire. 4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands together with the strands prepared in step 3 and twist together. 5. Solder the wires together with ROSIN core solder. 6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 7. Repeat steps 3 - 6 for the other wires. 8. Connect the body harness to the wheel speed sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Technical Service Bulletins > All Technical Service Bulletins for ABS Light: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously > Page 5570 9. Test drive the vehicle and verify proper operation of the ABS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-18-97 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Technical Service Bulletins > Page 5571 ABS Light: Description and Operation The ABS warning lamp will normally illuminate for one to two seconds when the ignition switch is first turned to the On position. Any time the Controller Anti-Lock Brake (CAB) detects a condition which results in a shutdown of the ABS function (other than when the ignition switch is first turned to the On position), it will activate the ABS warning lamp. When the lamp is on, only the anti-lock function of the brake system is affected. The base brake system and ability to stop the vehicle will not be affected. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations Fig. 19 Engine Compartment Wiring Mounted on left fender side shield. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Locations > Page 5575 ABS Main Relay: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect wiring harness electrical connectors from relays, then remove screw securing relay assembly to left front inner fender. 3. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Pump <--> [Brake Fluid Pump] > Component Information > Description and Operation ABS Pump: Description and Operation The pump/motor assembly is located under the hydraulic assembly at the rear lefthand side of the engine compartment. This electrically operated pump takes low pressure brake fluid from the hydraulic assembly reservoir and pressurizes it for storage in two accumulators for power assist and anti-lock braking. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Pump <--> [Brake Fluid Pump] > Component Information > Description and Operation > Page 5579 ABS Pump: Service and Repair The pump/motor cannot be serviced independently from the modulator (hydraulic control unit). If it is not function properly, the entire unit must be replaced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump Relay > Component Information > Locations Brake Fluid Pump Relay: Locations Fig. 19 Engine Compartment Wiring Mounted on left fender side shield. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations Diagnostic Connector - ABS: Locations This ABS system has a self diagnostic connector located under the lefthand side of the instrument panel, left of the steering column. The diagnostic connector is a blue 6-way connector which can be connected to a DRB II readout box. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams ABS Module Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 5589 Electronic Brake Control Module: Description and Operation The Controller Anti-Lock Brake (CAB) is located on the front lefthand side of the engine compartment. The CAB uses the information from the wheel speed sensors to control the anti-lock brake system function. The CAB also monitors ABS operation and detects system faults. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 5590 Electronic Brake Control Module: Service and Repair 1. With ignition switch in Off position, disconnect both battery cables and remove battery, then remove battery tray from vehicle. 2. Remove Controller Anti-lock Brake (CAB) from battery tray support bracket. 3. Loosen bolt securing 60-way connector to CAB, then disconnect connector from CAB by pulling straight out. Do not twist connector. 4. Remove CAB with its mounting bracket from vehicle. 5. Reverse procedure to install, noting the following: a. Ensure ignition switch is still in Off position before connecting 60-way connector to CAB. b. Torque connector bolt to 38 inch lbs. and CAB assembly mounting bolt to 14 inch lbs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation Hydraulic Control Assembly - Antilock Brakes: Description and Operation This system uses an integral hydraulic assembly which contains the wheel circuit valves used for brake pressure modulation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) Replacement 1. Remove fresh air intake and air cleaner assembly from engine. 2. Remove windshield washer fluid reservoir, then disconnect electrical connectors from hydraulic assembly. 3. Drain as much fluid from hydraulic reservoir as possible. 4. Disconnect pump high pressure line from hydraulic unit. 5. Disconnect pump return hose from steel tube, then cap the end of the steel tube. 6. Disconnect all brakes tubes from hydraulic assembly. 7. Remove retainer clip from brake pedal pin. 8. Remove four hydraulic mounting unit nuts, then the hydraulic unit. 9. Reverse procedure to install, noting the following: a. Torque mounting bolts to 21 ft. lbs. b. Lubricate bearing surface of pedal pin with lubricant. c. Install new retainer clip on pedal pin. d. Torque brake tubes to hydraulic unit to 30 ft. lbs. e. Torque return hose clamp to 10 inch lbs. f. Torque high pressure hose to 12 ft. lbs. g. Bleed brake system as described in this chapter. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 5596 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Modulator Assembly Replacement 1. Raise and support vehicle, then disconnect battery cables at battery. 2. Remove battery hold-down and battery from battery tray, then remove battery tray and Controller Anti-Lock Brake (CAB) from tray support bracket. 3. Loosen battery tray support bracket to modulator assembly mounting bracket bolt, then the battery tray support bracket to frame rail bolt. 4. Lift battery tray support bracket out of vehicle, then remove battery acid shield from ABS modulator assembly. 5. Disconnect six brake tube fittings at modulator assembly, thread savers and proportioning valves, then remove brake tube bundle from modulator assembly. It is not necessary to loosen fittings at junction block. 6. Raise and support vehicle, then disconnect wiring harness 10-way connector at modulator assembly. 7. Remove bolt securing speed control servo to modulator bracket, then position servo aside. 8. Loosen two bolts securing front of modulator bracket to frame rail, then loosen two rear modulator bracket bolts. 9. Lower vehicle, then remove modulator assembly and bracket from vehicle. 10. If necessary, separate modulator assembly from mounting bracket. 11. Reverse procedure to install. Bleed base and anti-lock brake systems separately. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously Wheel Speed Sensor: Customer Interest ABS - Warning Light ON Continuously NO: 05-22-94 GROUP: Brakes EFFECTIVE DATE: Dec. 2, 1994 SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor Connector MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) SYMPTOM/CONDITION: Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles brake system will perform as a non-ABS equipped vehicle normally would during this condition. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair as necessary. If an ABS wheel speed sensor DTC is discovered: 1. Disconnect the 2 way connector of the suspect wheel speed sensor. 2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body harness connector. There should be resistance/interference felt between the male and female terminals. 3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic Procedures for further diagnostics. 4. If no resistance/interference is felt at one or both terminals, perform the repair procedure. PARTS REQUIRED: 1 4797997 Kit, Terminal Repair Kit Consists Of: 1 4625196 Terminal, Male 1 Connector/Wire Assembly 2 4778570 Tube, Heat Shrink REPAIR PROCEDURE: This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread female terminals. 1. Cut off the suspect body harness connector and discard. 2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and the new connector/wire assembly. 3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and spread the strands of the wire. 4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands together with the strands prepared in step 3 and twist together. 5. Solder the wires together with ROSIN core solder. 6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 7. Repeat steps 3 - 6 for the other wires. 8. Connect the body harness to the wheel speed sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously > Page 5605 9. Test drive the vehicle and verify proper operation of the ABS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-18-97 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: All Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5611 39 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5612 43 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5613 45 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5614 47 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5615 51 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5616 55 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5617 57 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5618 59 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5619 63 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5620 67 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5621 69 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5622 71 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5623 173 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5624 177 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5625 179 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5626 181 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5627 187 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5628 191 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5629 193 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5630 195 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5631 201 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5632 205 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5633 207 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5634 209 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5635 256 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously Wheel Speed Sensor: All Technical Service Bulletins ABS - Warning Light ON Continuously NO: 05-22-94 GROUP: Brakes EFFECTIVE DATE: Dec. 2, 1994 SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor Connector MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) SYMPTOM/CONDITION: Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles brake system will perform as a non-ABS equipped vehicle normally would during this condition. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair as necessary. If an ABS wheel speed sensor DTC is discovered: 1. Disconnect the 2 way connector of the suspect wheel speed sensor. 2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body harness connector. There should be resistance/interference felt between the male and female terminals. 3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic Procedures for further diagnostics. 4. If no resistance/interference is felt at one or both terminals, perform the repair procedure. PARTS REQUIRED: 1 4797997 Kit, Terminal Repair Kit Consists Of: 1 4625196 Terminal, Male 1 Connector/Wire Assembly 2 4778570 Tube, Heat Shrink REPAIR PROCEDURE: This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread female terminals. 1. Cut off the suspect body harness connector and discard. 2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and the new connector/wire assembly. 3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and spread the strands of the wire. 4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands together with the strands prepared in step 3 and twist together. 5. Solder the wires together with ROSIN core solder. 6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 7. Repeat steps 3 - 6 for the other wires. 8. Connect the body harness to the wheel speed sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously > Page 5640 9. Test drive the vehicle and verify proper operation of the ABS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-18-97 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 050694 > Apr > 94 > Antilock Brake System - Wheel Speed Sensor Diagnosis Wheel Speed Sensor: All Technical Service Bulletins Antilock Brake System - Wheel Speed Sensor Diagnosis NO: 05-06-94 GROUP: Brakes DATE: Apr. 1, 1994 SUBJECT: Bendix Antilock-4 Wheel Speed Sensor Diagnosis MODELS: 1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1994 (AP) Shadow/Shadow Convertible/Sundance 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH BENDIX ANTILOCK-4 ABS. DISCUSSION: Bendix Antilock-4 ABS wheel speed sensors that have been returned under warranty for inspection have been and are continuing to be tested. An unusually large number of these wheel speed sensors are being found to have no defects. The following steps must be followed when diagnosing Bendix Antilock-4 ABS equipped vehicles: The diagnostic manual MUST be followed without exception. No shortcuts should be used during the diagnostic procedure. All diagnostic work Must begin with test "1A". All diagnostic work MUST end with "VER-1A". Following the above steps will ensure correct diagnosis of Bendix Antilock-4 ABS issues as well as preventing an unnecessary increase in Expense Per Unit Repaired (EPUR) for your dealership. POLICY: Information only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 051793A > Dec > 93 > ABS - Wheel Speed Sensor Applications Wheel Speed Sensor: All Technical Service Bulletins ABS - Wheel Speed Sensor Applications NO.: 05-17-93 Rev. A GROUP: Brakes DATE: Dec. 22, 1993 SUBJECT: Left Front Wheel Speed Sensor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-17-93 DATED NOV. 12, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1991-1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN ANTILOCK BRAKE SYSTEM (ABS). DISCUSSION: On the vehicles listed above, there are two wheel speed sensors specified for the left front wheel, depending upon the model year. The difference between the two parts is the length of the wiring, and they should not be interchanged. P/N 4683057 has longer wiring and must be used only on **1993 and** 1994 model vehicles. If this part is used on prior model year vehicles the wiring may become damaged. P/N 4509213 must be used only on 1991 ** and 1992 ** model vehicles. If this part is used on a ** later ** model vehicle, the wiring is too short and would have to be routed improperly to connect to the vehicle wiring harness. This may cause damage to the wheel speed sensor wiring. This bulletin supersedes any information in the Mopar Parts Catalog or PAIS at this time. A parts catalog bulletin is being developed and the parts catalog will be revised at a later date. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: All Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5654 39 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5655 43 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5656 45 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5657 47 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5658 51 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5659 55 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5660 57 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5661 59 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5662 63 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5663 67 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5664 69 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5665 71 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5666 173 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5667 177 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5668 179 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5669 181 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5670 187 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5671 191 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5672 193 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5673 195 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5674 201 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5675 205 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5676 207 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5677 209 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5678 256 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 050694 > Apr > 94 > Antilock Brake System - Wheel Speed Sensor Diagnosis Wheel Speed Sensor: All Technical Service Bulletins Antilock Brake System - Wheel Speed Sensor Diagnosis NO: 05-06-94 GROUP: Brakes DATE: Apr. 1, 1994 SUBJECT: Bendix Antilock-4 Wheel Speed Sensor Diagnosis MODELS: 1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1994 (AP) Shadow/Shadow Convertible/Sundance 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH BENDIX ANTILOCK-4 ABS. DISCUSSION: Bendix Antilock-4 ABS wheel speed sensors that have been returned under warranty for inspection have been and are continuing to be tested. An unusually large number of these wheel speed sensors are being found to have no defects. The following steps must be followed when diagnosing Bendix Antilock-4 ABS equipped vehicles: The diagnostic manual MUST be followed without exception. No shortcuts should be used during the diagnostic procedure. All diagnostic work Must begin with test "1A". All diagnostic work MUST end with "VER-1A". Following the above steps will ensure correct diagnosis of Bendix Antilock-4 ABS issues as well as preventing an unnecessary increase in Expense Per Unit Repaired (EPUR) for your dealership. POLICY: Information only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 051793A > Dec > 93 > ABS - Wheel Speed Sensor Applications Wheel Speed Sensor: All Technical Service Bulletins ABS - Wheel Speed Sensor Applications NO.: 05-17-93 Rev. A GROUP: Brakes DATE: Dec. 22, 1993 SUBJECT: Left Front Wheel Speed Sensor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-17-93 DATED NOV. 12, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1991-1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN ANTILOCK BRAKE SYSTEM (ABS). DISCUSSION: On the vehicles listed above, there are two wheel speed sensors specified for the left front wheel, depending upon the model year. The difference between the two parts is the length of the wiring, and they should not be interchanged. P/N 4683057 has longer wiring and must be used only on **1993 and** 1994 model vehicles. If this part is used on prior model year vehicles the wiring may become damaged. P/N 4509213 must be used only on 1991 ** and 1992 ** model vehicles. If this part is used on a ** later ** model vehicle, the wiring is too short and would have to be routed improperly to connect to the vehicle wiring harness. This may cause damage to the wheel speed sensor wiring. This bulletin supersedes any information in the Mopar Parts Catalog or PAIS at this time. A parts catalog bulletin is being developed and the parts catalog will be revised at a later date. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 5687 Wheel Speed Sensor: Description and Operation The wheel speed sensors are located at each wheel and transmit wheel speed information to the Controller Anti-Lock Brake (CAB). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front 1. Raise and support vehicle, then remove wheel and tire assembly. Fig. 252 Front Wheel Speed Sensor Assembly 2. Remove screw from clip that retains sensor wiring grommet, then pull sensor grommet from fenderwell. 3. Disconnect electrical connector, then remove two screws retaining sensor wiring routing tube. 4. Remove sensor head screw, then the sensor head from steering knuckle. NOTE: If sensor head is seized, use a punch and gently rock sensor back and forth until free. Do not use pliers on sensor head. 5. Reverse procedure to install. Coat sensor with suitable high temperature E.P. grease and torque mounting bolt to 5 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5690 Wheel Speed Sensor: Service and Repair Rear 1. Raise and support vehicle, then remove wheel and tire assembly. 2. Remove sensor wiring grommet retainer bracket, then pull sensor grommet from underbody. 3. Disconnect electrical connector, then remove wiring to frame rail attaching bracket. 4. Remove rear axle U-bolt nuts, then the sensor assembly mounting bracket. 5. Remove sensor head screw, then the sensor head from steering knuckle. If sensor head is seized, use a punch and gently rock sensor back and forth until free. Do not use pliers on sensor head. 6 Reverse procedure to install, noting the following: a. Torque sensor mounting bolt to 5 ft. lbs. b. Torque U-bolt nuts to 65 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > Brakes - Bendix ABS System Bleeding Procedure Revision Brake Bleeding: Technical Service Bulletins Brakes - Bendix ABS System Bleeding Procedure Revision NUMBER: 05-01-94 GROUP: Brakes DATE: May 27, 1994 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1994 Town & Country, Caravan and Voyager Service Manual - Publication No. 81-370-4105 DESCRIPTION OF CHANGES Bendix Antilock 4 Bleed Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > Brakes - Bendix ABS System Bleeding Procedure Revision > Page 5695 5-76 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > Brakes - Bendix ABS System Bleeding Procedure Revision > Page 5696 5-77 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > Brakes - Bendix ABS System Bleeding Procedure Revision > Page 5697 5-78 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding Brake Bleeding: Service and Repair About Brake System Bleeding WHEN BLEEDING BRAKES REMEMBER... - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always flush and bleed the brake hydraulic sys. when servicing the brakes, because: Brake fluid absorbs moisture from the air, after 3-4 years of service the water content of the brake fluid may be as high as 6-7%. This significantly reduces the boiling point of the brake fluid which may result in a soft pedal or brake failure during prolonged or severe braking. Corrosion deposits and other contaminants gradually build up inside of the brake hydraulic sys. Check the bottom of the master-cylinder reservoir for a build up of fine black silt. If any is present the brake fluid should be flushed. - Never reuse brake fluid that has been drained from the brake system. DOT 3,4 or DOT 5 As a general rule DOT 5 brake fluid should not be used in vehicles recommending DOT 3 or 4 type fluid. DOT 5 brake fluid is silicone based. DOT 3 (standard) and DOT 4 (heavy-duty) are glycol-based. DOT 5 can be distinguished from conventional brake fluids by its purple color (which comes from a dye). DOT 5 silicone brake fluid won't mix with glycol-based brake fluid (creating concern over sludging if all old fluid isn't removed when a system is refilled with silicone). Silicone does not absorb moisture. DOT 5 brake fluid does not become contaminated with moisture over time as conventional DOT 3 and 4 brake fluids do. Silicone is also chemically inert, nontoxic and won't damage paint like conventional brake fluid. It also has a higher boiling point. Because of this, it is often marketed as a premium "lifetime" brake fluid. It is often used to preserve brake systems in antique vehicles and those that sit for long periods of time between use. Silicone also has slightly different physical properties and compressibility, making it unsuitable for ABS systems calibrated to work with DOT 3 or 4 brake fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 5700 Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures Brake System Bleeding The content of this article reflects the changes called out by TSB 05-01-94. The base brake system must be bled anytime air is permitted to enter the hydraulic system. However, anti-lock brake system components should only be bled if the hydraulic control unit has been removed or if there is reason to believe that air has entered the unit. The ABS portion of the braking system must be bled separately. Under most circumstances, only the base brake system will require bleeding. If the anti-lock brake system must be bled, proceed as follows: 1. Bleed base brake system, then remove battery, battery tray, support bracket and acid shield. 2. Using suitable jumper cables, reconnect battery to vehicle battery cables, then connect DRB scan tool to diagnostic connector. Use extreme caution to avoid arcs and shorts against vehicle body when battery is connected through cables. 3. Using DRB, ensure Controller Antilock Brake (CAB) has no stored diagnostic trouble codes. 4. Bleed modulator primary check valve circuit, then the secondary check valve circuit as follows: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 5701 Fig. 242 Primary Check Valve Circuit Bleed Screw Location Fig. 243 Secondary Check Valve Circuit Bleed Screw Location a. Connect clear bleed tube to check valve circuit bleed screw, then place other end of tube in a clear glass container partially filled with clean brake fluid. b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure while loosening check valve circuit bleed screw one full turn. c. When brake pedal bottoms, tighten bleed screw, then release pedal. Do not release pedal until bleed screw is tight. d. Repeat procedure until brake fluid flowing through tube appears bubble-free and clean, then torque modulator assembly secondary bleed screw Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 5702 to 80 in. lbs. Do not remove bleed hose before screw is tight. 5. Bleed modulator primary sump circuit as follows: Fig. 244 Primary Sump Circuit Bleed Screw Location a. Connect clear bleed tube to primary sump circuit bleed screw, then place other end of tube in a clear glass container partially filled with clean brake fluid. b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure while loosening primary sump circuit bleed screw one full turn. c. Using DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Primary Circuit." Right front and left rear solenoids will fire alternately for approximately five seconds. d. Continue to select "Primary Circuit" on DRB until brake fluid flowing through bleed tube is bubble-free or until brake pedal bottoms. e. If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure. f. Torque primary sump bleed screw to 80 in. lbs., then release brake pedal and remove bleed tube from screw. Do not release pedal until bleed screw is tight. 6. Bleed modulator assembly primary accumulator circuit as follows: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 5703 Fig. 245 Primary Accumulator Circuit Bleed Screw Location a. Connect clear bleed tube to primary accumulator circuit bleed screw, then place other end of tube in a clear glass container partially filled with clean brake fluid. b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure. c. Using DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Primary Circuit Valves." Right front and left rear solenoids will fire alternately for approximately five seconds. d. Loosen primary accumulator circuit bleed screw one full turn. e. Continue bleeding primary accumulator circuit until brake fluid flowing through bleed tube is bubble-free or until brake pedal bottoms. f. If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure. g. Tighten primary accumulator bleed screw, then release brake pedal. Do not release pedal until bleed screw is tight. h. Pump brake pedal repeatedly, then depress pedal and exert a constant heavy force while opening primary accumulator circuit bleed screw one full turn. i. Without using DRB or allowing modulator solenoids to fire, bleed primary accumulator circuit until brake fluid flowing through tube appears bubble-free and clean. j. When brake fluid appears as specified, torque primary accumulator bleed screw to 80 in. lbs. and release brake pedal. Do not release brake pedal until bleed screw is tight. 7. Bleed modulator assembly secondary sump circuit as follows: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 5704 Fig. 246 Secondary Sump Circuit Bleed Screw Location a. Connect clear bleed tube to secondary sump circuit bleed screw, then place other end of tube in a clear glass container partially filled with clean brake fluid. b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure while loosening secondary sump circuit bleed screw one full turn. c. Using DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Secondary Circuit Valves." Left front and right rear solenoids will fire alternately for approximately five seconds. d. Continue to select "Secondary Circuit Valves" on DRB until brake fluid flowing through bleed tube is bubble-free or until brake pedal bottoms. e. If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure. f. Torque secondary sump bleed screw to 80 in. lbs., then release brake pedal and remove bleed tube from screw. Do not release pedal until bleed screw is tight. 8. Bleed modulator assembly secondary accumulator circuit as follows: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 5705 Fig. 247 Secondary Accumulator Circuit Bleed Screw Location a. Connect clear bleed tube to secondary accumulator circuit bleed screw, then place other end of tube in a clear glass container partially filled with clean brake fluid. b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure. c. Using DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Secondary Circuit Valves." Left front and right rear solenoids will fire alternately for approximately five seconds. d. Loosen secondary accumulator circuit bleed screw one full turn. e. Continue bleeding secondary accumulator circuit until brake fluid flowing through bleed tube is bubble-free or until brake pedal bottoms. f. If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure. g. Tighten secondary accumulator bleed screw, then release brake pedal. Do not release pedal until bleed screw is tight. h. Pump brake pedal repeatedly, then depress pedal and exert a constant heavy force while opening secondary accumulator circuit bleed screw one full turn. i. Without using DRB or allowing modulator solenoids to fire, bleed secondary accumulator circuit until brake fluid flowing through tube appears bubble-free and clean. j. When brake fluid appears as specified, torque secondary accumulator bleed screw to 80 in. lbs. and release brake pedal. Do not release brake pedal until bleed screw is tight. 9. Remove bleed tube and container, then install battery acid shield, tray support bracket, tray and battery. Pressure Bleeding When bleeding ABS systems use only diaphragm type bleed pressure bleeder. 1. Turn ignition switch to Off position, then pump brake pedal a minimum of 40 times to de-pressurize hydraulic accumulator. 2. Attach bleeding equipment to brake reservoir. 3. Connect a suitable transparent hose to bleeder valve on left rear wheel cylinder and submerge other end in a glass container partially filled with clean brake fluid. 4. Turn pressure bleeder On, open brake bleed screw 3/4 to one turn. Allow brake fluid to flow until clear and bubble free. 5. Continue to bleed right rear, left front, then right front brakes in that order. 6. Turn Off pressure bleeder, then slowly bleed off pressure from equipment. 7. Remove pressure bleeder from vehicle, ensure proper fluid level in master cylinder. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 5706 Brake Bleeding: Service and Repair Pressure Bleeding (Preferred Procedure) When bleeding ABS systems use only diaphragm type bleed pressure bleeder. 1. On models with anti-lock brakes, turn ignition switch to Off position, then pump brake pedal a minimum of 40 times to de-pressurize hydraulic accumulator. 2. On all models, attach bleeding equipment to brake reservoir. 3. Connect a suitable transparent hose to bleeder valve on left rear wheel cylinder and submerge other end in a glass container partially filled with clean brake fluid. 4. Turn pressure bleeder On, then open brake bleed screw 3/4 to one turn. Allow brake fluid to flow until clear and bubble free. 5. Continue to bleed right rear, left front, then right front brakes in that order. 6. Turn Off pressure bleeder, then slowly bleed off pressure from equipment. 7. Remove pressure bleeder from vehicle, ensure proper fluid level in master cylinder. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation Brake Warning Indicator: Description and Operation The brake warning light is designed to light only when either: The parking brake is applied with the ignition key turned "ON". - One of the two service brake systems has failed. Bulb Check The instrument panel bulb can be checked each time the ignition switch is turned to the start position or the parking brake is set. Pressure Differential Warning Light Switch Purpose The function of the Pressure Differential Switch is to alert the driver to a malfunction in the brake system. Operation The hydraulic brake system is split diagonally. The left front and right rear brakes are part of one system and the right front and left rear are part of another. Both systems are routed through, but hydraulically separated by the Pressure Differential Switch. If hydraulic pressure is lost in one system, the warning light switch will activate a red light on the instrument panel, when the brake pedal is depressed. At this point the brakes require service. - However, since the brake systems are split diagonally the vehicle will retain 50% of its stopping capability in the event of a failure in either half. The warning light switch is the latching type. It will automatically recenter itself after the repair is made and the brake pedal Is depressed. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Bore and Piston Dimensions Brake Caliper: Specifications Caliper Bore I.D. 2.36 in Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Bore and Piston Dimensions > Page 5715 Brake Caliper: Specifications Brake Hose To Caliper 24 ft.lb Brake Hose To Intermediate Bracket 8 ft.lb Brake Line Fittings 12 ft.lb Caliper Pin Guide Bolts 30 ft.lb Caliper Adapter Bolts 160 ft.lb Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 5716 Disc Brake Caliper Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 5717 Brake Caliper: Testing and Inspection WITH CALIPER ON VEHICLE Check for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any ruptures of piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper assembly and install a new seal and boot, (and piston if corroded or scored). Check the mating surfaces of the abutments on the caliper and adapter. If corroded or rusty, clean surfaces with wire brush. Inspect braking surfaces of disc. Check the caliper dust boot and caliper pin bushings to determine if they are in good condition. Replace if they are damaged, dry, or brittle. WITH CALIPER REMOVED Cleaning Clean all parts using alcohol or a suitable solvent and blow dry, using compressed air. Blow out all drilled passages and bores. NOTE: Whenever a caliper has been disassembled, a new boot and seal must be installed at reassembly. Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion, can usually be cleared with crocus cloth. - Bores that have deep scratches or scoring should be honed, providing the diameter of the bore is not increased more than 0.0254 mm (0.001 inch). - If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation Removal For additional information see Removal Notes. See: Fundamentals and Basics Disc Brake Caliper Assembly 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies. 3. Reach to the inside of the caliper and pull it outboard as far as you can. This will push the piston back into the bore of the caliper, making removal of caliper easier. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5720 Fig 1 Removing And Installing Caliper Guide Pins 4. Remove caliper guide pin bolts. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5721 Fig 2 Loosening Caliper Assembly From Adapter And Rotor 5. After removing caliper guide pin bolts, lift the caliper away from the braking disc with a pry bar or screwdriver. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5722 Fig 3 Removing Or Installing Caliper Assembly 6. Remove caliper from disc and adapter by sliding caliper assembly out and away from braking disc and adapter. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5723 Fig 4 Storing Caliper 7. Support caliper firmly to prevent weight of caliper from damaging the flexible hose. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5724 Fig 5 Removing And Installing Outboard Shoe Assembly 8. Remove the outboard shoe assembly from the caliper adapter. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5725 Fig 6 Removing And Installing Braking Disc 9. Remove the braking disc (rotor) from the hub by pulling it straight off the wheel mounting studs. Fig 7 Removing And Installing Inboard Shoe Assembly 10. Remove the inboard shoe assembly by sliding it out along the bottom adapter abutment until brake shoe assembly loosens from anti-rattle clip. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5726 Fig 8 Remove Or Install Anti-rattle Clip 11. Remove the anti-rattle clip from the top adapter abutment. Installation For additional information see Installation Notes. See: Fundamentals and Basics Disc Brake Caliper Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5727 1. Thoroughly clean both adapter abutment rails. If there is any build-up of rust on the adapter abutment rails, remove it using a wire brush DO NOT SAND RAILS. 2. Lubricate both adapter ways with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. Fig 8 Remove Or Install Anti-rattle Clip 3. Install the anti-rattle clip on the upper abutment of the caliper mounting adapter. 4. Remove the protective paper from the noise suppression gasket on both the inner and outer brake shoe assemblies (if equipped). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5728 Fig 7 Removing And Installing Inboard Shoe Assembly Fig 6 Removing And Installing Braking Disc Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5729 5. Install the new inboard brake shoe assembly on the adapter by sliding it along the adapter abutment. Be careful not to get any grease from the adapter way on the surface of the brake lining material. Be sure shoe assembly is correctly positioned against anti-rattle clip. 6. Install braking disc by sliding it over wheel studs until it is seated against the face of the hub. Fig 5 Removing And Installing Outboard Shoe Assembly 7. Slide the new outboard shoe assembly onto the adapter abutment. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5730 Fig 3 Removing Or Installing Caliper Assembly 8. Carefully lower caliper over disc brake rotor and shoe assemblies. Make sure that the the caliper guide pin bolts, bushings and sleeves are clear of the adapter. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5731 Fig 1 Removing And Installing Caliper Guide Pins CAUTION: Use care to avoid cross threading guide pins when installing. 7. Install guide pins through bushing caliper and adapter and tighten to 25-35 ft lb (34-37 Nm). 8. Install wheel and tire assembly. Tighten stud nuts in the proper sequence until all nuts are torqued to half specification. THIS IS IMPORTANT. Then repeat sequence to full specification. 7. Remove jackstands or lower hoist. CAUTION: Before moving vehicle, be sure it has a firm pedal. 8. Road test vehicle and make several stops to wear off any foreign material on the brakes and to seat the linings. The vehicle may pull to one side or the other if this is not done. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5732 Brake Caliper: Service and Repair Disassembly and Assembly Disassembly 1. Remove caliper from adapter and rotor. Do not disconnect brake hose from caliper. Support caliper at all times to prevent brake hose damage. 2. Position caliper away from rotor to prevent brake fluid spillage on machined surface, then place a small block of wood between caliper fingers to prevent piston damage during removal. 3. Gently depress brake pedal to force caliper piston out of bore, then secure brake pedal at any position below one inch of pedal travel to prevent master cylinder brake fluid loss. 4. Disconnect brake hose at caliper, then mount caliper assembly in a soft jawed vise. Do not apply excessive vise pressure; caliper damage will result. 5. Use a suitable screwdriver to remove dust boot, then use a plastic trim stick or other suitable non-metallic tool to pry piston seal out of piston bore groove. Using a metallic tool for this operation may score piston bore. 6. Discard dust boot and piston seal; then, if necessary, remove caliper bushing and sleeve assembly as follows: Removing Inner Sleeve From Bushing a. Push inner sleeve out of bushing far enough to grasp sleeve end, then pull sleeve from bushing. b. Gently collapse one side of bushing, then pull on opposite end to remove from caliper assembly. Assembly 1. Clamp caliper in soft jawed vise. Do not apply excessive vise pressure; caliper damage will result. 2. Immerse new piston seal in clean brake fluid, then install in piston bore groove. 3. Coat new piston boot with clean brake fluid, then position boot over piston and install piston in caliper bore. Apply uniform force when pressing piston into bore. 4. Position dust boot in caliper piston counterbore, then drive boot into counterbore using piston caliper boot installer tool No. C-4689 and handle tool No. C-4171, or equivalents. 5. Install guide pin sleeve bushings as follows: a. Fold bushing in half lengthwise at solid middle section, then carefully insert bushing into caliper assembly. b. Using fingers or a suitable soft dowel, unfold bushing to seat in caliper assembly. Ensure flanges are seated evenly on both sides of bushing hole. 6. Gently press guide pin sleeves through bushings until bushings seat in seal grooves, then ensure bushings and sleeves are installed properly by sliding each back and forth. Sleeves should slide easily and bushings should remain seated in grooves. 7. Install caliper as outlined under Brake Pad/Service and Repair. Cleaning, Inspecting & Honing Caliper Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5733 Honing Brake Caliper Piston Bore Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion, can usually be cleared with crocus cloth. - Bores that have deep scratches or scoring should be honed, using Tool C-4095, providing the diameter of the bore is not increased more than 0.0254 mm (0.001 inch). - If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. When using a hone: Coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff nonmetallic rotary brush. Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the caliper with brake fluid; wipe dry with a clean, lintless cloth and then clean a second time. Be sure to install the hone baffle before honing bore. The baffle is used to protect the hone stones from damage. Use extreme care in cleaning the caliper after honing. Inspection 1. Clean all caliper components in alcohol or other suitable solvent and wipe dry. Ensure bores and drilled passages are cleaned thoroughly. 2. Inspect piston bore for scoring or pitting. Crocus cloth may be used to remove minor scratches or corrosion. 3. If piston bore exhibits deep scratches or severe scoring, use caliper honing tool No. C-4095, or equivalent, to hone caliper bore. Do not increase bore diameter more than 0.001 inch. 4. If caliper piston bore is to be honed, honing tool stones and piston bore should be coated with clean brake fluid, and honing should be followed by cleaning with a stiff, non-metallic rotary brush. 5. If scoring and scratches cannot be removed without increasing piston bore beyond the specified limit, caliper must be replaced. 6. Replace caliper piston if scored or pitted. Kelsey-Hayes Double Pin Caliper Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5734 Disc Brake Caliper Assembly DISASSEMBLING CALIPER 1. Support caliper assembly on upper control arms on shop towels to absorb any hydraulic fluid loss. 2. Place a small piece of wood between the piston and caliper fingers. 3. Carefully depress brake pedal to hydraulically push piston out of bore (brake pedal will fall away when piston has passed bore opening). 4. Prop brake pedal to any position below the first inch of pedal travel -- to prevent loss of brake fluid. If both front caliper pistons are to be removed: a. Disconnect flexible brake line at frame bracket after removing piston. b. Plug brake tube and remove piston from opposite caliper. WARNING: Under no condition should air pressure be used to remove piston from bore! Personal Injury could result from such practice. 5. Disconnect brake flexible hose from the caliper. 6. To disassemble, mount caliper assembly in a vise equipped with protective jaws. CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5735 Fig. 10 Dust Boot Removal 7. Support caliper and remove dust boot and discard. Removing Piston Seal From Caliper 8. Using a plastic trim stick, work piston seal out of its groove in piston bore. Discard old seal. Do not use a screwdriver or other metal tool for this operation, because of possibility of scratching piston bore or burring edges of seal groove. Bushing and Sleeve Assembly Service NOTE: The bushing and sleeve assembly is a sealed for life unit. To service this unit: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5736 Removing Inner Sleeve From Bushing a. Push out and then pull the inner sleeve from the inside of the bushing using your fingers as shown. Removing Bushing From Caliper b. Using your fingers collapse one side of the bushing while pulling on the opposite side to remove the bushing from the caliper assembly. CLEANING AND INSPECTION Clean all parts using alcohol or a suitable solvent and blow dry, using compressed air. Blow out all drilled passages and bores. NOTE: Whenever a caliper has been disassembled, a new boot and seal must be installed at reassembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5737 Honing Brake Caliper Piston Bore Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion, can usually be cleared with crocus cloth. - Bores that have deep scratches or scoring should be honed, providing the diameter of the bore is not increased more than 0.0254 mm (0.001 inch). - If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. When using a hone: Coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff nonmetallic rotary brush. Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the caliper with brake fluid; wipe dry with a clean, lintless cloth and then clean a second time. ASSEMBLING CALIPER 1. Clamp caliper in vise (with protector jaws). CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. Installing New Piston Seal In Caliper 2. Dip new piston seal in clean brake fluid and install in groove in bore. Seal should be positioned at one area in groove and gently worked around the groove, using fingers until properly seated. CAUTION: NEVER USE AN OLD PISTON SEAL. (Be sure that fingers are clean and seal is not twisted or rolled). 3. Coat new piston boot with clean brake fluid leaving a generous amount inside of boot. 4. Position dust boot over piston after coating with brake fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5738 Fig. 4 Caliper piston installation 5. Install piston into bore pushing it past the piston seal until it bottoms in the bore. CAUTION: Force must be applied uniformly to avoid cocking the piston. 6. Position dust boot in counterbore. Using a hammer and Tool C4842 with C4171 handle or equivalent, drive boot into counterbore. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5739 Folded Caliper Guide Pin Bushing Guide Pin Sleeve Bushing Installation a. Fold the bushing in half lengthwise at the solid middle section of the bushing. Removing Bushing From Caliper Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5740 Installing Caliper Guide Pin Bushing b. Using your fingers insert the folded bushing into the caliper assembly. Making sure the solid section of the bushing is fully seated into the bushing hole of the caliper assembly. Do not use a sharp object to perform this step due to possible damage to the bushing. Bushing Correctly Installed In Caliper c. Unfold the bushing using your fingers or wooden dowel until the bushing is fully seated into the caliper assembly with the flanges seated evenly on both sides of the bushing holes in the caliper assembly. Fig 7 Installing Caliper Sleeves Guide Pin Sleeve Installation a. Install the sleeve into one end of the bushing until the seal area of the bushing is past the seal groove in the sleeve. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5741 b. Holding the convoluted end of the bushing with one hand. Push the sleeve through the bushing until the one end of the bushing is fully seaated into the seal groove on the one end of the sleeve. Fig 8 Installed Caliper Bushing Sleeve c. Holding the sleeve in place work the other end of the bushing over the end of the sleeve and into the seal groove. Be sure the other end of the bushing did not come out of the seal groove in the sleeve. c. When the sleeve is seated properly into the bushing. The sealed for life bushing can be held between your finger and easily slid back and forth without the bushing seal unseating from the sleeve. NOTE: Before installing caliper assembly on vehicle, inspect braking disc for runout, thickness, and thickness variation. 7. Install caliper assembly. CAUTION: Always use new seal washers when installing brake hose to caliper. 8. Install brake hose to caliper using new seal washers, tighten banjo bolt to 33 Nm (24 ft lb). 9. Bleed the brake system. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes Brake Caliper: Fundamentals and Basics Removal Notes When Removing the Caliper, Remember... - Prior to removing the calipers, remove/siphon brake fluid from master-cylinder until the reservoir is only 1/3 full. - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always replace all brake linings on an axle. Never replace only one wheel. Unequal lining thickness between wheels on the same axle will result in a strong steering pull when the brakes are applied. - Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. - When forcing the piston back into the caliper, open the bleeder valve first. Corrosion and other deposits accumulate inside of the caliper. If the bleeder valve is not opened when the piston is forced back into the caliper, these deposits will be forced back through the brake lines and into the master-cylinder. - When pushing the pistons back into the caliper with the bleeder screw open, a stream of brake fluid will be expelled from the bleeder screw for 2-3 feet. Use a drip pan and be careful not to "shoot" brake fluid onto the vehicle's finish. A cleaner method is to use a piece of clear plastic hose and a glass or plastic jar to catch the expelled fluid. - Upon removal, Do Not allow the calipers to hang by the flexible brake hoses. The brake hoses can be damaged easily by this practice. These hoses are double walled, damage to the interior pressure hose will not be visible. - Do not depress the brake pedal with either caliper removed from the rotor. The caliper pistons will be inadvertently expelled from the caliper. If this occurs rebuild or replace the caliper, do not attempt to insert the piston back into the caliper. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 5744 Brake Caliper: Fundamentals and Basics Installation Notes WHEN INSTALLING CALIPERS AND PADS, REMEMBER... - Clean and lubricate caliper slide joint/pins with high temperature silicone grease: Unlike drum brakes, disc brakes do not utilize a spring to withdraw the pads/linings when the brake pedal is released. Disc brakes rely on the elasticity of the piston seals, and the unrestricted movement of the caliper slide assemblies to release the brakes. If the slide joints/pins are not cleaned and lubricated properly the disc brake linings will drag upon the release of the brake pedal. This will result in overheated brakes and premature brake wear. Disc Brake Mechanical Force Diagram NOTE: Floating calipers require free and unrestricted movement on the caliper mounting. Floating or sliding calipers have pistons only on one side of the rotor. The first part of the piston's travel forces the inner pad against the rotor, then further travel forces the movable part of the caliper to pull the outer pad against the rotor. High temperature silicone lubricant must be used. Low temperature grease can melt and contaminate the pads and rotors, or can bake into a very hard substance which binds the slides. Petroleum based grease can cause the slide boots to soften and swell. - Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. Anti-squeal Coating - Apply an anti-squeal coating to the back side of the pads/linings. This coatings acts as an insulator to dampen high frequency vibrations that are generated during normal braking. These compounds are highly effective in preventing brake squeal. - Many professional repair shops recommend always rebuilding or replacing the calipers when replacing the brake linings, because: When the pistons are forced back into the calipers, the piston seals are dragged across any corrosion or abrasives that may be deposited on the inside of the caliper. Damage to the seals may not be initially evident. As the new brake linings begin to wear, the piston is gradually withdrawn from the caliper. This results in the piston seals again being dragged across the layer of corrosion and deposits. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 5745 Calipers which are not rebuilt or replaced have a higher probability of sticking or leaking. - Check to ensure the bleeder screw is not frozen prior to reinstalling caliper. Freeing a stuck bleeder screw is much easier with the caliper removed from the vehicle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Minimum Combined Thickness Of Lining And Backing 0.313 in Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 5749 Brake Pad: Service Precautions Do not get any oil or grease on the linings. It is recommended that both front wheel sets be replaced whenever a respective shoe and lining is worn or damaged. Inspect and, if necessary, replace rear brake linings also. If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation Brake Pad: Service and Repair Removal and Installation Removal For additional information see Removal Notes. See: Brake Caliper/Fundamentals and Basics Disc Brake Caliper Assembly 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies. 3. Reach to the inside of the caliper and pull it outboard as far as you can. This will push the piston back into the bore of the caliper, making removal of caliper easier. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 5752 Fig 1 Removing And Installing Caliper Guide Pins 4. Remove caliper guide pin bolts. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 5753 Fig 2 Loosening Caliper Assembly From Adapter And Rotor 5. After removing caliper guide pin bolts, lift the caliper away from the braking disc with a pry bar or screwdriver. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 5754 Fig 3 Removing Or Installing Caliper Assembly 6. Remove caliper from disc and adapter by sliding caliper assembly out and away from braking disc and adapter. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 5755 Fig 4 Storing Caliper 7. Support caliper firmly to prevent weight of caliper from damaging the flexible hose. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 5756 Fig 5 Removing And Installing Outboard Shoe Assembly 8. Remove the outboard shoe assembly from the caliper adapter. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 5757 Fig 6 Removing And Installing Braking Disc 9. Remove the braking disc (rotor) from the hub by pulling it straight off the wheel mounting studs. Fig 7 Removing And Installing Inboard Shoe Assembly 10. Remove the inboard shoe assembly by sliding it out along the bottom adapter abutment until brake shoe assembly loosens from anti-rattle clip. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 5758 Fig 8 Remove Or Install Anti-rattle Clip 11. Remove the anti-rattle clip from the top adapter abutment. Installation For additional information see Installation Notes. See: Brake Caliper/Fundamentals and Basics Disc Brake Caliper Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 5759 1. Thoroughly clean both adapter abutment rails. If there is any build-up of rust on the adapter abutment rails, remove it using a wire brush DO NOT SAND RAILS. 2. Lubricate both adapter ways with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. Fig 8 Remove Or Install Anti-rattle Clip 3. Install the anti-rattle clip on the upper abutment of the caliper mounting adapter. 4. Remove the protective paper from the noise suppression gasket on both the inner and outer brake shoe assemblies (if equipped). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 5760 Fig 7 Removing And Installing Inboard Shoe Assembly Fig 6 Removing And Installing Braking Disc Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 5761 5. Install the new inboard brake shoe assembly on the adapter by sliding it along the adapter abutment. Be careful not to get any grease from the adapter way on the surface of the brake lining material. Be sure shoe assembly is correctly positioned against anti-rattle clip. 6. Install braking disc by sliding it over wheel studs until it is seated against the face of the hub. Fig 5 Removing And Installing Outboard Shoe Assembly 7. Slide the new outboard shoe assembly onto the adapter abutment. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 5762 Fig 3 Removing Or Installing Caliper Assembly 8. Carefully lower caliper over disc brake rotor and shoe assemblies. Make sure that the the caliper guide pin bolts, bushings and sleeves are clear of the adapter. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 5763 Fig 1 Removing And Installing Caliper Guide Pins CAUTION: Use care to avoid cross threading guide pins when installing. 7. Install guide pins through bushing caliper and adapter and tighten to 25-35 ft lb (34-37 Nm). 8. Install wheel and tire assembly. Tighten stud nuts in the proper sequence until all nuts are torqued to half specification. THIS IS IMPORTANT. Then repeat sequence to full specification. 7. Remove jackstands or lower hoist. CAUTION: Before moving vehicle, be sure it has a firm pedal. 8. Road test vehicle and make several stops to wear off any foreign material on the brakes and to seat the linings. The vehicle may pull to one side or the other if this is not done. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 5764 Brake Pad: Service and Repair Cleaning and Inspection Remove one of the front wheels and inspect the brake disc, caliper and linings. If linings are contaminated replace them with fresh linings. If a visual inspection does not adequately determine lining condition, remove the pads and measure the total thickness of lining and backing at the thinnest point. If combined thickness of lining and backing is 7.95 mm (5/16 in) or less replace pads. CAUTION: Do not get any oil or grease on the linings. NOTES: The wheel bearings should be inspected at this time and repacked if necessary. - It is recommended that all front wheel pads -- both sides -- be replaced whenever any front pad is worn or damaged. - Rear brake linings should be inspected when a brake problem is suspected. - Uneven wear of linings on different sides of the caliper or vehicle may indicate a sticking caliper. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Specifications Brake Disc: Specifications Nominal Thickness 0.939 - 0.949 in Minimum Thickness 0.881 in Rotor Runout 0.005 in Hub Runout 0.003 in Thickness Variation 0.0005 in Rotor Finish 15-80 micro-in Fig 1 Checking Total Indicated Runout (TIR) Fig 3 Checking Hub Runout Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Specifications > Page 5768 Fig 5 Checking Disc Thickness Fig 7 Refacing Brake Disc -- Final Finish Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Service Precautions > Brake Disc Service Brake Disc: Service Precautions Brake Disc Service Servicing of disc brakes is extremely critical due to the close tolerances required in machining the brake disc to ensure proper brake operation. The maintenance of these close controls on the friction surfaces is necessary to prevent brake roughness. In addition, the surface finish must be non-directional and maintained at a micro-inch finish. This close control of the rubbing surface finish is necessary to avoid pulls and erratic performance and promote long lining life and equal lining wear of both left and right brakes. Refinishing of the rubbing surfaces should not be attempted unless precision equipment, capable of measuring in micro-inches (millionths of an inch) is available. To check runout of a disc, mount a dial indicator on a convenient part (steering knuckle, tie rod, disc brake caliper housing) so that the plunger of the dial indicator contacts the disc at a point one inch from the outer edge. If the total indicated runout exceeds specifications, install a new disc. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Service Precautions > Brake Disc Service > Page 5771 Brake Disc: Service Precautions Brake Roughness The most common cause of brake chatter on disc brakes is a variation in thickness of the disc. If roughness or vibration is encountered during highway operation or if pedal pumping is experienced at low speeds, the disc may have excessive thickness variation. To check for this condition, measure the disc at 8 points with a micrometer at a radius approximately one inch from edge of disc. If thickness measurements vary more than specifications allow, the disc should be replaced with a new one. Excessive lateral runout of braking disc may cause a "knocking back" of the pistons, possibly creating increased pedal travel and vibration when brakes are applied. Before checking the runout, wheel bearings should be adjusted. Be sure to make the adjustment according to the recommendations given in that section. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Service Precautions > Page 5772 Brake Disc: Testing and Inspection NOTE: If a vehicle has not been driven for a period of time, the discs will rust in the area not covered by the lining and cause noise and chatter. NOTE: Some discoloration or wear of the disc surface is normal and does not require re-surfacing when linings are replaced. CAUTION: Any servicing of the braking disc requires extreme care to maintain the braking disc within service tolerances to ensure proper brake action. BEFORE REFINISHING OR REFACING A BRAKING DISC INSPECT FOR: - Scoring, rust, impregnation of lining material and worn ridges. - Excessive wear and scoring of the disc CAUTION: Excessive wear and scoring of the disc can cause temporary improper lining contact if ridges are not removed before installation of new brake shoe assemblies. - Runout or wobble CAUTION: Excessive runout or wobble in a disc can increase pedal travel due, to piston knockback This will increase guide pin bushing wear due to tendency of caliper to follow disc wobble. - Thickness variation (Parallelism). NOTE: Thickness variation in a disc can also result in pedal pulsation, chatter and surge due to variation in brake output when disc section is uneven. - Dishing or distortion (Flatness). NOTE: Dishing or distortion can be caused by extreme heat and abuse of the brakes. SPECIFICATION - See: Specifications Fig 1 Checking Total Indicated Runout (TIR) MEASURING TOTAL DISC RUNOUT ON VEHICLE: NOTE: On Vehicle, Braking Disc (rotor) Runout is the combination of the individual runout of the hub face and the runout of the disc. The hub and disc are separable. NOTE: Before checking the runout, wheel bearings should be adjusted. 1. Remove the wheel and reinstall the lug nuts to tighten the disc to the hub. 2. Mount dial indicator with adapter on steering arm with plunger contacting disc braking surface approximately one inch from edge of disc. 3. Check lateral runout (both sides of disc). - Runout should not exceed 0.13mm (0.005 inch). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Service Precautions > Page 5773 - If total runout is in exceeds specification check the lateral runout of the hub face. Fig 2 Marking Brake Disc And Wheel Stud For Reassembly MEASURING LATERAL RUNOUT OF THE HUB FACE: 1. Before removing disc, make a chalk mark across both the disc and one wheel stud, on the high side of runout, so you'll know exactly how the disc and hub was originally mounted. 2. Remove disc from hub. Fig 3 Checking Hub Runout 3. Install dial indicator with adapter on steering arm with stem contacting hub face near outer diameter (care must be taken to position dial indicator stem outside the stud circle but inside the chamfer on the hub rim. Runout should not exceed 0.05mm (0.002 inch). If runout exceeds this specification, hub must be replaced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Service Precautions > Page 5774 Fig 4 Indexing Disc And Wheel Stud - If hub runout does not exceed this specification, install disc on hub with chalk marks 180 degrees apart. 4. Finally, recheck runout of disc to see if runout is now within specifications. - If runout is in excess of specifications, install a new disc or reface disc, being careful to remove as little as possible from each side of disc. Remove equal amounts from each side of disc. Do not reduce thickness below the recommended minimum thickness. NOTE: Thickness variation measurements of disc should be made in conjunction with runout. Fig 5 Checking Disc Thickness THICKNESS VARIATION MEASUREMENTS Measure thickness of disc at twelve (12) equal points with a micrometer at a radius approximately 25.4 mm (one (1) inch) from edge of disc. If thickness measurements vary by more than 13 mm (0.0005 inch) disc should be removed and resurfaced, or a new disc installed. - If cracks or burned spots are evident in the disc, disc must be replaced. - For additional information on how to use a micrometer, see Fundamentals and Basics.See: Fundamentals and Basics NOTE: Light scoring and/or wear Is acceptable: If heavy scoring or warping is evident, the disc must be refinished or replaced. - If cracks are evident in the disc, replace the disc. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Service and Repair > Rotor Removal and Installation Brake Disc: Service and Repair Rotor Removal and Installation Removal 1. Raise vehicle on hoist or jackstands. 2. Remove wheel and tire assembly. Hanging Caliper Out Of The Way 3. Remove caliper assembly, but do not disconnect brake line. 4. Suspend caliper from wire hook or loop to avoid strain on flexible hose. Fig 2 Marking Brake Disc And Wheel Stud For Reassembly 5. Mark disc and stud for assembly. 6. Remove braking disc from drive flange studs. Installation Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Service and Repair > Rotor Removal and Installation > Page 5777 Fig 2 Marking Brake Disc And Wheel Stud For Reassembly 1. Slide brake disc assembly on drive flange studs. Pay attention to marks for assembly. 2. Clean both sides of braking disc with alcohol or suitable solvent. 3. Install caliper assembly. For additional information see Installation Notes. See: Fundamentals and Basics Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Service and Repair > Rotor Removal and Installation > Page 5778 Brake Disc: Service and Repair Rotor Refinishing CAUTION: When refacing a disc brake rotor the required 0.10 mm (0.004 inch) TIR (Total Indicator Reading) and 0.013 mm (0.0005 in.) thickness variation limits MUST BE MAINTAINED. Extreme care in the operation of rotor turning equipment is required. Resurfacing Notes: This operation can be used when the disc surface is rusty or has lining deposits. A sanding disc attachment will remove surface contamination without removing much material. - It will generally follow variations in thickness which are in the disc. Refacing Braking Disc Notes: Rotors do not have to be refaced whenever a disc brake is relined. - If the rotor surface is deeply scored or warped or there is a complaint of brake roughness the rotor should be refaced. - The collets, shafts and adaptors on the lathe and the bearing cups in the rotor MUST be clean and free from any chips or contamination. - When mounting the disc on the lathe, strict attention to the manufacturer's instructions is required. - If the disc is not mounted properly the run-out will be worse after refacing than before refacing. Fig 6 Refacing Brake Disc Fig 7 Refacing Brake Disc -- Final Finish Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Service and Repair > Rotor Removal and Installation > Page 5779 - The use of a double straddle cutter which machines both sides of the disc at the same time is highly recommended. Fig 8 Minimum Disc Thickness Marking Fig 8 Minimum Disc Thickness Marking Measurements and specifications when servicing the braking disc: NOTE: All braking discs (rotors) have markings for minimum allowable thickness cast on an un-machined surface. This marking includes 0.76 mm (0.030 inch) allowable disc wear beyond the recommended 0.76 mm (0.030 inch) of disc refacing. - This surface may be as shown or on an alternate surface. Minimum Allowable Thickness ................................................................................................................................................... 22.4mm (0.881 in) NOTE: For additional information on how to use a micrometer, see Fundamentals and Basics. See: Fundamentals and Basics Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Fundamentals and Basics > How to Use A Micrometer Brake Disc: Fundamentals and Basics How to Use A Micrometer CONSTRUCTION The spindle on a micrometer is moved in or out by rotating the thimble or ratchet. The thread pitch on the spindle is 40 threads per inch. A single full rotation of the thimble extends or retracts the spindle one thread or 1/40 of an inch (0.025, 25 thousands). The thimble is divided into 25 equal divisions. Rotating the thimble one division will extend or retract the spindle 1/25 of a thread. (1/25) x (1/40)inch = 1/1000 inch (0.001), one division on the thimble is equal to 0.001 inches. HOW TO READ As the thimble is rotated out it uncovers a scale on the sleeve. Each major division on the scale is 1/10 of an inch (0.100) Each major division is separated into 4 minor divisions, each equal to 25/1000 of an inch (0.025). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Fundamentals and Basics > How to Use A Micrometer > Page 5782 A full rotation will move the thimble exactly one minor division on the sleeve. To read the micrometer you must add the measurement which is visible on the sleeve to the measurement which is showing on the thimble In the example the sleeve measurement is 0.250 inches and the thimble measurement is 0.017 inches. The total measurement is then equal to the two measurements combined, 0.267 inches. NOTES The accuracy and calibration of a micrometer can be altered easily by applying too much pressure to the spindle. Use the thimble to quickly rotate the spindle in until it is near the rotor. - Use the ratchet to rotate the spindle into contact with the rotor. - The ratchet has a built in slip which prevents excessive stress or pressure from developing. Calibrate the micrometer regularly. Most micrometers come with a precision dowel which allows for easy and accurate adjustments. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Fundamentals and Basics > How to Use A Micrometer > Page 5783 Brake Disc: Fundamentals and Basics Installation Notes WHEN INSTALLING A ROTOR/DISC, REMEMBER... Thoroughly clean the rotors with brake cleaner. - Any grease or brake fluid which comes in contact with the rotor should be thoroughly cleaned prior to installing the new pads/linings. - Grease and other contaminants become lodged in the microscopic pores of the rotor's surface. This prolongs the brake-in time of the new linings and contaminates the friction material. - Commercially produced aerosol brake cleaners should be used to clean the rotor. Unlike carburetor cleaner or other petroleum based solvents, brake cleaner does not leave a residue on the rotor's surface. Recheck the wheel bearings once the tires are installed. - With the vehicle raised and properly supported, grasp the tire at the top and bottom and attempt to rock them back and forth. There should be no detectable lateral (wobble) movement. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Fundamentals and Basics > How to Use A Micrometer > Page 5784 Brake Disc: Fundamentals and Basics Tightening Notes WHEN TIGHTENING LUG NUTS, REMEMBER... Always tighten the lug nuts to the correct torque specification. Lightly lubricate the studs with an anti-seize compound to ensure proper torque and prevent damage to the threads. Tighten in an alternating pattern around the wheel until the wheel is centered on the studs. Do your final tightening with a torque wrench. When servicing disc brakes it is very important to properly torque the wheel assembly. Lug nuts which are installed with an air impact tool are often over-torqued. This may distort the rotor and result in excessive lateral runout (rotor wobble) and a pedal pulsation upon braking. Recheck the wheel bearings once the tires are installed. With the vehicle raised and properly supported, grasp the tire at the top and bottom and attempt to rock them back and forth. There should be no detectable lateral (wobble) movement. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications Backing Plate: Specifications Brake support plate to rear axle bolts .......................................................................................................................................................... 109 Nm (80 ft lb) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 5789 Backing Plate: Testing and Inspection Inspect backing plate shoe contact surface for grooves that may restrict shoe movement and cannot be removed by lightly sanding with emery cloth or other suitable abrasive. If backing plate exhibits above condition, it should be replaced. Also inspect for signs of cracks, warpage and excessive rust, indicating need for replacement. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 5790 Backing Plate: Service and Repair Fig 9 Removing Brake Cable From Backing Plate REMOVAL 1. With wheel and brake drum removed, remove brake shoe assemblies and disconnect brake cable from parking brake lever. 2. Using a suitable tool such as an aircraft type hose clamp compress the flared legs of cable retainer and pull brake cable out of support plate. 3. Disconnect hydraulic brake tube from wheel cylinder. 4. Remove support to wheel cylinder attaching nuts and washers. 5. Remove brake support and spindle mounting screws. 6. Remove brake support, spindle and gasket from rear axle. Fig 1 Rear Wheel Brake INSTALLATION 1. Install support plate, spindle and gasket to rear axle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 5791 Brake Shoe Contact Pads On Backing (Support) Plate 2. Apply RTV sealant around wheel cylinder mounting surface. 3. Install wheel cylinder and attach hydraulic brake tube. 4. Insert parking brake cable into support plate and attach cable to parking brake lever. 5. Install brake shoes on support plate. 6. Install brake drum and wheel. Adjust and bleed brakes. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Adjuster > Component Information > Testing and Inspection Brake Adjuster: Testing and Inspection ADJUSTER MECHANISM Inspect all components for rust, corrosion, bends and fatigue. Replace as necessary. On adjuster mechanism equipped with adjuster cable, inspect cable for kinks, fraying or elongation of eyelet and replace as necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Testing and Inspection Brake Drum: Testing and Inspection Fig 5 Drum Maximum Diameter Specification NOTE: Any brake drum sufficiently out of round to cause vehicle vibration or noise while braking, or showing taper should also be machined, removing only enough stock to true up the brake drum. If the braking surface diameter is within specifications: Drums should be cleaned and inspected for cracks, scores, deep grooves, taper, out of round and heat spotting. If drums are cracked or heat spotted, they must be replaced. - Minor scores should be removed with sandpaper. - Grooves and large scores can only be removed by machining with special equipment, as long as the braking surface is within specifications stamped on brake drum outer surface. Measuring Drum Runout and Diameter NOTE: Measure the drum runout and diameter with an accurate gauge. Maximum Variation There should be no variation in the drum diameter greater than 0.O5mm (0.002 in.). Maximum Runout Drum runout should not exceed 0.15mm (0.006 in.) out of round. - If the drum runout or diameter variation exceed these values the drum should be refaced. Maximum Single Cut For best results in eliminating the irregularities that cause brake roughness and surge, the amount of material removed during a single cut should be limited to 0.13mm (0.005 in.). Final Cut When the entire braking surface has been cleaned a final cut of 0.0254mm (0.001 in.) will assure a good drum surface providing the equipment used is capable of giving the precision required for resurfacing brake drums. Deeper cuts are permissible for the sole purpose of removing deep score marks. CAUTION: Do not reface more than 1.52mm (0.60 in.) over the standard drum diameter. NOTE: If one brake drum is machined, the other should also be machined to the same diameter to maintain equal braking forces. After a brake drum is machined: Wipe the braking surface diameter with a cloth soaked in denatured alcohol. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Removal Brake Drum: Service and Repair Brake Drum Removal For additional information see Notes, Warnings, and Hints. Fig. 9 Release Brake Adjuster Fig. 6 Release type brake adjuster 1. Remove the tire and wheel assembly. 2. Remove rear plug from brake adjusting access hole. 3. Insert a thin screwdriver into brake adjusting hole and hold adjusting lever away from notches of adjusting screw. 4. Insert Tool C-3784 or equivalent, into brake adjusting hole and engage notches of brake adjusting screw. Release brake by prying down with adjusting tool. NOTE: The rear hubs are held on by the axle nut which should be covered by a dust cap. Fig. 3 Wheel bearing assembly 5. Remove rear hub and drum assembly. 6. Inspect brake lining for wear, shoe alignment, or contamination from grease or brake fluid. Inspect wheel bearings for rust or signs of wear. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Removal > Page 5800 Brake Drum: Service and Repair Brake Drum Installation For additional information see Notes, Warnings, and Hints. NOTE: Reinstallation of retaining clips is not necessary. Fig. 3 Wheel bearing assembly 1. Install hub and drum assembly. - Torque adjusting nut to 270 inch lbs. while rotating wheel. - Stop wheel and loosen adjusting nut. Tighten adjusting nut finger tight. End play should be 0.0001---0.0020 inch. - Install castle lock with slots aligned with cotter pin hole. - Install cotter pin and grease cap. 2. Install wheel and tire assembly. - When tightening wheel stud nuts, using a criss-cross tightening sequence as shown. - Tighten all stud nuts to one-half specified torque. Repeat, fully tightening to specified torque. Fig 6 Wheel Stud Tightening Sequence - Wheel stud lug nut torque 129 Nm (95 ft lb) 3. Adjust rear brakes. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Removal > Page 5801 Brake Drum: Service and Repair Brake Drum Refinishing Fig 5 Drum Maximum Diameter Specification CAUTION: Do not reface more than 1.52mm (0.60 in.) over the standard drum diameter. NOTE: If one brake drum is machined, the other should also be machined to the same diameter to maintain equal braking forces. NOTE: All drums will show markings of maximum allowable diameter. For example, a drum will have a marking of MAX. Dia. 231.0mm (9.09 in.). This marking includes 0.76mm (0.030 in.) for allowable drum wear beyond the recommended 1.52mm (0.060 in.) of drum refacing. Measuring Drum Runout and Diameter NOTE: Measure the drum runout and diameter with an accurate gauge. Maximum Variation There should be no variation in the drum diameter greater than 0.O5mm (0.002 in.). Maximum Runout Drum runout should not exceed 0.15mm (0.006 in.) out of round. If the drum runout or diameter variation exceed these values the drum should be refaced. Maximum Single Cut For best results in eliminating the irregularities that cause brake roughness and surge, the amount of material removed during a single cut should be limited to 0.13mm (0.005 in.). Final Cut When the entire braking surface has been cleaned a final cut of 0.0254mm (0.001 in.) will assure a good drum surface providing the equipment used is capable of giving the precision required for resurfacing brake drums. Deeper cuts are permissible for the sole purpose of removing deep score marks. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service Precautions Brake Shoe: Service Precautions Prior to removing brake shoes it is recommended that a suitable clip or restraining device be applied to the wheel cylinders to prevent wheel cylinder pistons from being pushed out of their bores. Do not intermix automatic adjuster components from side to side. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service Precautions > Page 5805 Brake Shoe: Testing and Inspection Inspect brake linings for excessive wear, damage, oil, grease or brake fluid contamination. If any of the above conditions exists, brake linings should be replaced. Do not attempt to replace only one set of brake shoes; they should be replaced as an axle set only to maintain equal braking forces. Examine brake shoe webbing, hold-down and return springs for signs of overheating indicated by a slight blue color. If any component exhibits signs of overheating, replace hold-down and return springs with new ones. Overheated springs lose their pull and could cause brake linings to wear out prematurely. Inspect all springs for sags, bends and external damage, and replace as necessary. Inspect hold-down retainers and pins for bends, rust and corrosion. If any of the above conditions exist, replace retainers and pins. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service Precautions > Page 5806 Brake Shoe: Adjustments The rear brakes are self-adjusting. An initial adjustment is necessary after the brake shoes have been relined or replaced, or when the length of the star wheel adjuster has been changed during other service operations. To adjust the rear brakes, proceed as follows: 1. Raise and support vehicle. 2. Remove adjusting hole covers from brake support plates. 3. Release parking brake and back off adjustment to slacken cable. 4. Insert brake adjusting tool No. C-3784, or equivalent, through adjusting hole and into contact with star wheel of adjusting screw. 5. Move handle of tool upward to turn star wheel until a slight drag is felt while turning wheel. 6. Insert a suitable tool into brake adjusting hole and push adjusting lever out of engagement with star wheel. Use caution not to bend adjusting lever or distort lever spring. 7. Using adjusting tool, back off star wheel until no brake shoe drag is felt while turning wheel. 8. Adjust parking brake as outlined under Parking Brake/Adjustments, then install adjusting hole covers. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation Brake Shoe: Service and Repair Brake Shoe Removal and Installation Removal For additional information see Notes, Warnings, and Hints. Fig 1 Rear Wheel Brake Fig 2 Removing And Installing Shoe Return Springs TIP: Unless you are very familiar with this rear brake system you should consider servicing one side at a time. This will leave you an example of how the pieces go back together. NOTE: Support plates and park brake assemblies are NOT SYMMETRICALLY OPPOSITE. Right Side: Parking brake cable enters the support plate at the rear and attaches to the lever attached to the primary shoe. Right side support and cable assembly is color coded gray. - Left Side: Parking brake cable enters the support plate at the front (traditional) and attaches to the lever attached to the secondary shoe. Left side support and cable assembly is color coded black. 1. Remove rear wheel, and hub and drum assembly. 2. Using tool C-3785 or equivalent, remove brake shoe return springs. NOTE: For additional information see Brake Spring Removal and Installation Notes. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 5809 NOTE: The secondary shoe return spring overlaps the primary shoe return spring. 3. Slide the eye of automatic adjuster cable off anchor and then unhook from adjusting lever. 4. Remove cable, overload spring, cable guide and anchor plate. 5. Disengage adjusting lever from spring by sliding forward to clear pivot, then working out from under spring. 6. Remove spring from pivot. 7. Remove shoe to shoe spring from secondary shoe web and disengage form primary shoe web. 8. Remove spring. 9. Disengage primary and secondary shoes and remove adjusting star wheel assembly from shoes. Fig 3 Removing And Installing Shoe Retainers, Springs And Nails 10. Remove brake shoe retainers, springs and nails using Tool C-4070 or equivalent and remove from support. 11. Remove parking brake lever from secondary shoe. 12. Remove shoes. 13. Disengage parking brake lever from the parking brake cable. Installation For additional information see Notes, Warnings, and Hints. Fig 1 Rear Wheel Brake Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 5810 Brake Shoe Contact Pads On Backing (Support) Plate NOTE: Lubricate the six shoe tab contact pads on support plate with a thin film of MOPAR MultiPurpose Lubricant, Part number 2932524 or equivalent. NOTE: Support plates and park brake assemblies are NOT SYMMETRICALLY OPPOSITE. - Right Side: Parking brake cable enters the support plate at the rear and attaches to the lever attached to the primary shoe. Right side support and cable assembly is color coded gray. - Left Side: Parking brake cable enters the support plate at the front (traditional) and attaches to the lever attached to the secondary shoe. Left side support and cable assembly is color coded black. Fig 3 Removing And Installing Shoe Retainers, Springs And Nails 1. Slide primary shoe against support plate, at the same time engage shoe web with wheel cylinder piston and against anchor. Using tool C-4070 or equivalent install shoe retaining nail, retainer, and spring. NOTE: For additional information see Brake Spring Removal and Installation Notes. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 5811 Fig 7 Removing Of Installing Parking Brake Strut And Spring 2. Install anchor plate over anchor, then install eye of adjuster cable over anchor. Fig 2 Removing And Installing Shoe Return Springs 3. Engage primary shoe return spring in web of shoe and install free end over anchor. 4. Slide parking brake strut into slot in parking brake lever. Slide anti-rattle spring over free end of strut. 5. Engage parking brake lever with cable. Install parking brake lever into rectangular hole of secondary brake shoe (left side) or primary shoe (right side). Installing Brake Shoes Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 5812 6. Slide secondary shoe into position and engage with wheel cylinder piston and free end of strut. Install shoe retaining nail, retainer, and spring. 7. Insert protruding hole rim of cable guide into hole in secondary shoe web. Holding guide in position, engage secondary shoe return spring through both, hole in guide, and hole in web. Using Tool C-3785, install spring over anchor. Be sure cable guide remains flat against shoe web and that secondary spring overlaps primary). - Using pliers, squeeze ends of spring loops (around anchor) until parallel. 8. Install adjusting star wheel assembly between primary and secondary shoes, with star wheel next to secondary shoe. - The left star wheel adjusting stud end is stamped "L" (indicating its position on the vehicle) and the star wheel is cadmium plated. - The right star wheel is black and the adjusting stud end is stamped "R". Install shoe to shoe spring between shoes. - Engage primary shoe first. 9. Install adjusting lever spring over pivot pin on shoe web. Install adjusting lever under spring and over pivot pin. Slide lever slightly rearward to lock in position. 10. Thread adjuster cable over guide and hook end of overload spring in lever. - Be sure eye of cable is pulled tight against anchor and in a straight line with guide. 11. Check operation of automatic application adjuster by pulling adjuster cable rearward. Star wheel should rotate upwards. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 5813 Brake Shoe: Service and Repair Cleaning and Inspection Brake Linings 1. Inspect components for damage and unusual wear. Replace as necessary. 2. Inspect wheel cylinders. Boots which are torn, cut or heat damaged indicate need for wheel cylinder replacement. Peel back lower edge of boot. If fluid spills out, cup leakage is indicated and wheel cylinder should be replaced. NOTE: A slight amount of fluid is always present and considered normal, acting as a lubricant for the cylinder pistons. 3. Inspect backing plate for evidence of axle seal leakage. If leakage exists, refer to individual vehicle chapter for axle seal replacement procedure. 4. Inspect backing plate attaching bolts, and ensure they are tight. 5. Inspect adjuster screw operation. If satisfactory, lightly lubricate adjusting screw and washer with suitable brake lube. If operation is unsatisfactory, replace. 6. Using fine emery cloth or other suitable abrasive, clean rust and dirt from shoe contact surfaces on backing plate. Brake Linings & Springs Inspect brake linings for excessive wear, damage, oil, grease or brake fluid contamination. If any of the above conditions exists, brake linings should be replaced. Do not attempt to replace only one set of brake shoes; they should be replaced as an axle set only to maintain equal braking forces. Examine brake shoe webbing, hold-down and return springs for signs of overheating indicated by a slight blue color. If any component exhibits signs of overheating, replace hold-down and return springs with new ones. Overheated springs lose their pull and could cause brake linings to wear out prematurely. Inspect all springs for sags, bends and external damage, and replace as necessary. Inspect hold-down retainers and pins for bends, rust and corrosion. If any of the above conditions exist, replace retainers and pins. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Bore Diameter Wheel Cylinder: Specifications Rear Wheel Cylinder Bore Diameter 0.75 in Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Bore Diameter > Page 5818 Wheel Cylinder: Specifications Wheel Cylinder To Support Plate 6 ft.lb Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Page 5819 Fig 3 Wheel Cylinder Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal Wheel Cylinder: Service and Repair Wheel Cylinder Removal Fig 1 Brake Tube Disconnected 1. In case of a leak, remove brake shoes, (replace if soaked with grease or brake fluid). 2. Disconnect brake tube from wheel cylinder. Fig 2 Removing Or Installing Wheel Cylinder 3. Remove wheel cylinder attaching bolts, then pull wheel cylinder assembly out of support. For additional information see Notes, Warnings, and Hints. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 5822 Wheel Cylinder: Service and Repair Wheel Cylinder Installation For additional information see Notes, Warinings, and Hints. Brake Shoe Contact Pads On Backing (Support) Plate 1. Apply RTV sealant around wheel cylinder mounting surface. Fig 2 Removing Or Installing Wheel Cylinder Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 5823 Fig 1 Brake Tube Disconnected 2. Slide wheel cylinder into position on support. Install mounting screws and tighten as specified. 3. Connect brake tube to wheel cylinder. 4. Insert parking brake cable into support plate and attach cable to parking brake lever. 5. Install brake shoes on support plate. 6. Install brake drum and wheel. 7. Adjust and bleed brakes. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 5824 Wheel Cylinder: Service and Repair Cleaning and Inspection Fig 3 Wheel Cylinder 1. With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. 2. Block brake pedal in stroke position, visually check the boots for cuts, tears, or heat cracks. If any of the above conditions exist, the wheel cylinders should be completely cleaned, inspected and new parts installed. NOTE: A slight amount of fluid on the boot may be preservative fluid used at assembly and should not automatically be considered a leak. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 5825 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul For additional information see Notes, Warinings, and Hints. Fig 3 Wheel Cylinder NOTE: To perform service operations or inspections of the wheel cylinders, it will be necessary to remove the cylinders from the support plate and disassemble on the bench. CAUTION: Wheel cylinders with cup expanders must have cup expanders after any service procedures (reconditioning or replacement). DISASSEMBLING WHEEL CYLINDERS 1. Pry boots away from cylinders and remove. 2. Press In on one piston to force out other piston, cup, spring -- with cup expanders -- cup and piston. 3. Wash wheel cylinder, pistons, and spring in clean brake fluid or alcohol. - Clean thoroughly and blow dry with compressed air. CAUTION: Do not use a rag as lint from the rag will adhere to bore surfaces. 4. Inspect cylinder bore and piston for scoring and pitting. - Wheel cylinder bores and pistons that are badly scored or pitted should be replaced. - Cylinder walls that have light scratches, or show signs of corrosion, can usually be cleaned with crocus cloth, using a circular motion. - Black stains on the cylinder walls are caused by piston cups and will not impair operation of cylinder. ASSEMBLING WHEEL CYLINDERS Assembly Notes: Before assembling the pistons and new cups in the wheel cylinders, dip them in clean brake fluid. - If the boots are deteriorated, cracked or do not fit tightly on the push rods or the cylinder casting, install new boots. 1. Coat cylinder bore with clean brake fluid. 2. Install expansion spring with cup expanders in cylinder. Install cups in each end of cylinder with open end of cups facing each other. 3. Install piston in each end of cylinder having the flat face of each piston contacting the flat face of each cup, already installed. 4. Install a boot over each end of cylinder. Use care not to damage boot. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > Brakes - Bendix ABS System Bleeding Procedure Revision Brake Bleeding: Technical Service Bulletins Brakes - Bendix ABS System Bleeding Procedure Revision NUMBER: 05-01-94 GROUP: Brakes DATE: May 27, 1994 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1994 Town & Country, Caravan and Voyager Service Manual - Publication No. 81-370-4105 DESCRIPTION OF CHANGES Bendix Antilock 4 Bleed Procedure Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > Brakes - Bendix ABS System Bleeding Procedure Revision > Page 5831 5-76 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > Brakes - Bendix ABS System Bleeding Procedure Revision > Page 5832 5-77 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > Brakes - Bendix ABS System Bleeding Procedure Revision > Page 5833 5-78 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding Brake Bleeding: Service and Repair About Brake System Bleeding WHEN BLEEDING BRAKES REMEMBER... - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always flush and bleed the brake hydraulic sys. when servicing the brakes, because: Brake fluid absorbs moisture from the air, after 3-4 years of service the water content of the brake fluid may be as high as 6-7%. This significantly reduces the boiling point of the brake fluid which may result in a soft pedal or brake failure during prolonged or severe braking. Corrosion deposits and other contaminants gradually build up inside of the brake hydraulic sys. Check the bottom of the master-cylinder reservoir for a build up of fine black silt. If any is present the brake fluid should be flushed. - Never reuse brake fluid that has been drained from the brake system. DOT 3,4 or DOT 5 As a general rule DOT 5 brake fluid should not be used in vehicles recommending DOT 3 or 4 type fluid. DOT 5 brake fluid is silicone based. DOT 3 (standard) and DOT 4 (heavy-duty) are glycol-based. DOT 5 can be distinguished from conventional brake fluids by its purple color (which comes from a dye). DOT 5 silicone brake fluid won't mix with glycol-based brake fluid (creating concern over sludging if all old fluid isn't removed when a system is refilled with silicone). Silicone does not absorb moisture. DOT 5 brake fluid does not become contaminated with moisture over time as conventional DOT 3 and 4 brake fluids do. Silicone is also chemically inert, nontoxic and won't damage paint like conventional brake fluid. It also has a higher boiling point. Because of this, it is often marketed as a premium "lifetime" brake fluid. It is often used to preserve brake systems in antique vehicles and those that sit for long periods of time between use. Silicone also has slightly different physical properties and compressibility, making it unsuitable for ABS systems calibrated to work with DOT 3 or 4 brake fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 5836 Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures Brake System Bleeding The content of this article reflects the changes called out by TSB 05-01-94. The base brake system must be bled anytime air is permitted to enter the hydraulic system. However, anti-lock brake system components should only be bled if the hydraulic control unit has been removed or if there is reason to believe that air has entered the unit. The ABS portion of the braking system must be bled separately. Under most circumstances, only the base brake system will require bleeding. If the anti-lock brake system must be bled, proceed as follows: 1. Bleed base brake system, then remove battery, battery tray, support bracket and acid shield. 2. Using suitable jumper cables, reconnect battery to vehicle battery cables, then connect DRB scan tool to diagnostic connector. Use extreme caution to avoid arcs and shorts against vehicle body when battery is connected through cables. 3. Using DRB, ensure Controller Antilock Brake (CAB) has no stored diagnostic trouble codes. 4. Bleed modulator primary check valve circuit, then the secondary check valve circuit as follows: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 5837 Fig. 242 Primary Check Valve Circuit Bleed Screw Location Fig. 243 Secondary Check Valve Circuit Bleed Screw Location a. Connect clear bleed tube to check valve circuit bleed screw, then place other end of tube in a clear glass container partially filled with clean brake fluid. b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure while loosening check valve circuit bleed screw one full turn. c. When brake pedal bottoms, tighten bleed screw, then release pedal. Do not release pedal until bleed screw is tight. d. Repeat procedure until brake fluid flowing through tube appears bubble-free and clean, then torque modulator assembly secondary bleed screw Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 5838 to 80 in. lbs. Do not remove bleed hose before screw is tight. 5. Bleed modulator primary sump circuit as follows: Fig. 244 Primary Sump Circuit Bleed Screw Location a. Connect clear bleed tube to primary sump circuit bleed screw, then place other end of tube in a clear glass container partially filled with clean brake fluid. b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure while loosening primary sump circuit bleed screw one full turn. c. Using DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Primary Circuit." Right front and left rear solenoids will fire alternately for approximately five seconds. d. Continue to select "Primary Circuit" on DRB until brake fluid flowing through bleed tube is bubble-free or until brake pedal bottoms. e. If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure. f. Torque primary sump bleed screw to 80 in. lbs., then release brake pedal and remove bleed tube from screw. Do not release pedal until bleed screw is tight. 6. Bleed modulator assembly primary accumulator circuit as follows: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 5839 Fig. 245 Primary Accumulator Circuit Bleed Screw Location a. Connect clear bleed tube to primary accumulator circuit bleed screw, then place other end of tube in a clear glass container partially filled with clean brake fluid. b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure. c. Using DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Primary Circuit Valves." Right front and left rear solenoids will fire alternately for approximately five seconds. d. Loosen primary accumulator circuit bleed screw one full turn. e. Continue bleeding primary accumulator circuit until brake fluid flowing through bleed tube is bubble-free or until brake pedal bottoms. f. If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure. g. Tighten primary accumulator bleed screw, then release brake pedal. Do not release pedal until bleed screw is tight. h. Pump brake pedal repeatedly, then depress pedal and exert a constant heavy force while opening primary accumulator circuit bleed screw one full turn. i. Without using DRB or allowing modulator solenoids to fire, bleed primary accumulator circuit until brake fluid flowing through tube appears bubble-free and clean. j. When brake fluid appears as specified, torque primary accumulator bleed screw to 80 in. lbs. and release brake pedal. Do not release brake pedal until bleed screw is tight. 7. Bleed modulator assembly secondary sump circuit as follows: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 5840 Fig. 246 Secondary Sump Circuit Bleed Screw Location a. Connect clear bleed tube to secondary sump circuit bleed screw, then place other end of tube in a clear glass container partially filled with clean brake fluid. b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure while loosening secondary sump circuit bleed screw one full turn. c. Using DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Secondary Circuit Valves." Left front and right rear solenoids will fire alternately for approximately five seconds. d. Continue to select "Secondary Circuit Valves" on DRB until brake fluid flowing through bleed tube is bubble-free or until brake pedal bottoms. e. If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure. f. Torque secondary sump bleed screw to 80 in. lbs., then release brake pedal and remove bleed tube from screw. Do not release pedal until bleed screw is tight. 8. Bleed modulator assembly secondary accumulator circuit as follows: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 5841 Fig. 247 Secondary Accumulator Circuit Bleed Screw Location a. Connect clear bleed tube to secondary accumulator circuit bleed screw, then place other end of tube in a clear glass container partially filled with clean brake fluid. b. Pump brake pedal repeatedly, then depress pedal and exert medium to heavy pressure. c. Using DRB, select "Bleed ABS Hydraulic Unit" mode, then select "Secondary Circuit Valves." Left front and right rear solenoids will fire alternately for approximately five seconds. d. Loosen secondary accumulator circuit bleed screw one full turn. e. Continue bleeding secondary accumulator circuit until brake fluid flowing through bleed tube is bubble-free or until brake pedal bottoms. f. If brake pedal bottoms before expelled fluid appears bubble-free, repeat procedure. g. Tighten secondary accumulator bleed screw, then release brake pedal. Do not release pedal until bleed screw is tight. h. Pump brake pedal repeatedly, then depress pedal and exert a constant heavy force while opening secondary accumulator circuit bleed screw one full turn. i. Without using DRB or allowing modulator solenoids to fire, bleed secondary accumulator circuit until brake fluid flowing through tube appears bubble-free and clean. j. When brake fluid appears as specified, torque secondary accumulator bleed screw to 80 in. lbs. and release brake pedal. Do not release brake pedal until bleed screw is tight. 9. Remove bleed tube and container, then install battery acid shield, tray support bracket, tray and battery. Pressure Bleeding When bleeding ABS systems use only diaphragm type bleed pressure bleeder. 1. Turn ignition switch to Off position, then pump brake pedal a minimum of 40 times to de-pressurize hydraulic accumulator. 2. Attach bleeding equipment to brake reservoir. 3. Connect a suitable transparent hose to bleeder valve on left rear wheel cylinder and submerge other end in a glass container partially filled with clean brake fluid. 4. Turn pressure bleeder On, open brake bleed screw 3/4 to one turn. Allow brake fluid to flow until clear and bubble free. 5. Continue to bleed right rear, left front, then right front brakes in that order. 6. Turn Off pressure bleeder, then slowly bleed off pressure from equipment. 7. Remove pressure bleeder from vehicle, ensure proper fluid level in master cylinder. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 5842 Brake Bleeding: Service and Repair Pressure Bleeding (Preferred Procedure) When bleeding ABS systems use only diaphragm type bleed pressure bleeder. 1. On models with anti-lock brakes, turn ignition switch to Off position, then pump brake pedal a minimum of 40 times to de-pressurize hydraulic accumulator. 2. On all models, attach bleeding equipment to brake reservoir. 3. Connect a suitable transparent hose to bleeder valve on left rear wheel cylinder and submerge other end in a glass container partially filled with clean brake fluid. 4. Turn pressure bleeder On, then open brake bleed screw 3/4 to one turn. Allow brake fluid to flow until clear and bubble free. 5. Continue to bleed right rear, left front, then right front brakes in that order. 6. Turn Off pressure bleeder, then slowly bleed off pressure from equipment. 7. Remove pressure bleeder from vehicle, ensure proper fluid level in master cylinder. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Bore and Piston Dimensions Brake Caliper: Specifications Caliper Bore I.D. 2.36 in Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Bore and Piston Dimensions > Page 5847 Brake Caliper: Specifications Brake Hose To Caliper 24 ft.lb Brake Hose To Intermediate Bracket 8 ft.lb Brake Line Fittings 12 ft.lb Caliper Pin Guide Bolts 30 ft.lb Caliper Adapter Bolts 160 ft.lb Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 5848 Disc Brake Caliper Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 5849 Brake Caliper: Testing and Inspection WITH CALIPER ON VEHICLE Check for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any ruptures of piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper assembly and install a new seal and boot, (and piston if corroded or scored). Check the mating surfaces of the abutments on the caliper and adapter. If corroded or rusty, clean surfaces with wire brush. Inspect braking surfaces of disc. Check the caliper dust boot and caliper pin bushings to determine if they are in good condition. Replace if they are damaged, dry, or brittle. WITH CALIPER REMOVED Cleaning Clean all parts using alcohol or a suitable solvent and blow dry, using compressed air. Blow out all drilled passages and bores. NOTE: Whenever a caliper has been disassembled, a new boot and seal must be installed at reassembly. Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion, can usually be cleared with crocus cloth. - Bores that have deep scratches or scoring should be honed, providing the diameter of the bore is not increased more than 0.0254 mm (0.001 inch). - If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation Removal For additional information see Removal Notes. See: Fundamentals and Basics Disc Brake Caliper Assembly 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies. 3. Reach to the inside of the caliper and pull it outboard as far as you can. This will push the piston back into the bore of the caliper, making removal of caliper easier. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5852 Fig 1 Removing And Installing Caliper Guide Pins 4. Remove caliper guide pin bolts. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5853 Fig 2 Loosening Caliper Assembly From Adapter And Rotor 5. After removing caliper guide pin bolts, lift the caliper away from the braking disc with a pry bar or screwdriver. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5854 Fig 3 Removing Or Installing Caliper Assembly 6. Remove caliper from disc and adapter by sliding caliper assembly out and away from braking disc and adapter. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5855 Fig 4 Storing Caliper 7. Support caliper firmly to prevent weight of caliper from damaging the flexible hose. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5856 Fig 5 Removing And Installing Outboard Shoe Assembly 8. Remove the outboard shoe assembly from the caliper adapter. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5857 Fig 6 Removing And Installing Braking Disc 9. Remove the braking disc (rotor) from the hub by pulling it straight off the wheel mounting studs. Fig 7 Removing And Installing Inboard Shoe Assembly 10. Remove the inboard shoe assembly by sliding it out along the bottom adapter abutment until brake shoe assembly loosens from anti-rattle clip. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5858 Fig 8 Remove Or Install Anti-rattle Clip 11. Remove the anti-rattle clip from the top adapter abutment. Installation For additional information see Installation Notes. See: Fundamentals and Basics Disc Brake Caliper Assembly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5859 1. Thoroughly clean both adapter abutment rails. If there is any build-up of rust on the adapter abutment rails, remove it using a wire brush DO NOT SAND RAILS. 2. Lubricate both adapter ways with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. Fig 8 Remove Or Install Anti-rattle Clip 3. Install the anti-rattle clip on the upper abutment of the caliper mounting adapter. 4. Remove the protective paper from the noise suppression gasket on both the inner and outer brake shoe assemblies (if equipped). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5860 Fig 7 Removing And Installing Inboard Shoe Assembly Fig 6 Removing And Installing Braking Disc Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5861 5. Install the new inboard brake shoe assembly on the adapter by sliding it along the adapter abutment. Be careful not to get any grease from the adapter way on the surface of the brake lining material. Be sure shoe assembly is correctly positioned against anti-rattle clip. 6. Install braking disc by sliding it over wheel studs until it is seated against the face of the hub. Fig 5 Removing And Installing Outboard Shoe Assembly 7. Slide the new outboard shoe assembly onto the adapter abutment. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5862 Fig 3 Removing Or Installing Caliper Assembly 8. Carefully lower caliper over disc brake rotor and shoe assemblies. Make sure that the the caliper guide pin bolts, bushings and sleeves are clear of the adapter. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5863 Fig 1 Removing And Installing Caliper Guide Pins CAUTION: Use care to avoid cross threading guide pins when installing. 7. Install guide pins through bushing caliper and adapter and tighten to 25-35 ft lb (34-37 Nm). 8. Install wheel and tire assembly. Tighten stud nuts in the proper sequence until all nuts are torqued to half specification. THIS IS IMPORTANT. Then repeat sequence to full specification. 7. Remove jackstands or lower hoist. CAUTION: Before moving vehicle, be sure it has a firm pedal. 8. Road test vehicle and make several stops to wear off any foreign material on the brakes and to seat the linings. The vehicle may pull to one side or the other if this is not done. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5864 Brake Caliper: Service and Repair Disassembly and Assembly Disassembly 1. Remove caliper from adapter and rotor. Do not disconnect brake hose from caliper. Support caliper at all times to prevent brake hose damage. 2. Position caliper away from rotor to prevent brake fluid spillage on machined surface, then place a small block of wood between caliper fingers to prevent piston damage during removal. 3. Gently depress brake pedal to force caliper piston out of bore, then secure brake pedal at any position below one inch of pedal travel to prevent master cylinder brake fluid loss. 4. Disconnect brake hose at caliper, then mount caliper assembly in a soft jawed vise. Do not apply excessive vise pressure; caliper damage will result. 5. Use a suitable screwdriver to remove dust boot, then use a plastic trim stick or other suitable non-metallic tool to pry piston seal out of piston bore groove. Using a metallic tool for this operation may score piston bore. 6. Discard dust boot and piston seal; then, if necessary, remove caliper bushing and sleeve assembly as follows: Removing Inner Sleeve From Bushing a. Push inner sleeve out of bushing far enough to grasp sleeve end, then pull sleeve from bushing. b. Gently collapse one side of bushing, then pull on opposite end to remove from caliper assembly. Assembly 1. Clamp caliper in soft jawed vise. Do not apply excessive vise pressure; caliper damage will result. 2. Immerse new piston seal in clean brake fluid, then install in piston bore groove. 3. Coat new piston boot with clean brake fluid, then position boot over piston and install piston in caliper bore. Apply uniform force when pressing piston into bore. 4. Position dust boot in caliper piston counterbore, then drive boot into counterbore using piston caliper boot installer tool No. C-4689 and handle tool No. C-4171, or equivalents. 5. Install guide pin sleeve bushings as follows: a. Fold bushing in half lengthwise at solid middle section, then carefully insert bushing into caliper assembly. b. Using fingers or a suitable soft dowel, unfold bushing to seat in caliper assembly. Ensure flanges are seated evenly on both sides of bushing hole. 6. Gently press guide pin sleeves through bushings until bushings seat in seal grooves, then ensure bushings and sleeves are installed properly by sliding each back and forth. Sleeves should slide easily and bushings should remain seated in grooves. 7. Install caliper as outlined under Brake Pad/Service and Repair. Cleaning, Inspecting & Honing Caliper Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5865 Honing Brake Caliper Piston Bore Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion, can usually be cleared with crocus cloth. - Bores that have deep scratches or scoring should be honed, using Tool C-4095, providing the diameter of the bore is not increased more than 0.0254 mm (0.001 inch). - If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. When using a hone: Coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff nonmetallic rotary brush. Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the caliper with brake fluid; wipe dry with a clean, lintless cloth and then clean a second time. Be sure to install the hone baffle before honing bore. The baffle is used to protect the hone stones from damage. Use extreme care in cleaning the caliper after honing. Inspection 1. Clean all caliper components in alcohol or other suitable solvent and wipe dry. Ensure bores and drilled passages are cleaned thoroughly. 2. Inspect piston bore for scoring or pitting. Crocus cloth may be used to remove minor scratches or corrosion. 3. If piston bore exhibits deep scratches or severe scoring, use caliper honing tool No. C-4095, or equivalent, to hone caliper bore. Do not increase bore diameter more than 0.001 inch. 4. If caliper piston bore is to be honed, honing tool stones and piston bore should be coated with clean brake fluid, and honing should be followed by cleaning with a stiff, non-metallic rotary brush. 5. If scoring and scratches cannot be removed without increasing piston bore beyond the specified limit, caliper must be replaced. 6. Replace caliper piston if scored or pitted. Kelsey-Hayes Double Pin Caliper Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5866 Disc Brake Caliper Assembly DISASSEMBLING CALIPER 1. Support caliper assembly on upper control arms on shop towels to absorb any hydraulic fluid loss. 2. Place a small piece of wood between the piston and caliper fingers. 3. Carefully depress brake pedal to hydraulically push piston out of bore (brake pedal will fall away when piston has passed bore opening). 4. Prop brake pedal to any position below the first inch of pedal travel -- to prevent loss of brake fluid. If both front caliper pistons are to be removed: a. Disconnect flexible brake line at frame bracket after removing piston. b. Plug brake tube and remove piston from opposite caliper. WARNING: Under no condition should air pressure be used to remove piston from bore! Personal Injury could result from such practice. 5. Disconnect brake flexible hose from the caliper. 6. To disassemble, mount caliper assembly in a vise equipped with protective jaws. CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5867 Fig. 10 Dust Boot Removal 7. Support caliper and remove dust boot and discard. Removing Piston Seal From Caliper 8. Using a plastic trim stick, work piston seal out of its groove in piston bore. Discard old seal. Do not use a screwdriver or other metal tool for this operation, because of possibility of scratching piston bore or burring edges of seal groove. Bushing and Sleeve Assembly Service NOTE: The bushing and sleeve assembly is a sealed for life unit. To service this unit: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5868 Removing Inner Sleeve From Bushing a. Push out and then pull the inner sleeve from the inside of the bushing using your fingers as shown. Removing Bushing From Caliper b. Using your fingers collapse one side of the bushing while pulling on the opposite side to remove the bushing from the caliper assembly. CLEANING AND INSPECTION Clean all parts using alcohol or a suitable solvent and blow dry, using compressed air. Blow out all drilled passages and bores. NOTE: Whenever a caliper has been disassembled, a new boot and seal must be installed at reassembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5869 Honing Brake Caliper Piston Bore Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion, can usually be cleared with crocus cloth. - Bores that have deep scratches or scoring should be honed, providing the diameter of the bore is not increased more than 0.0254 mm (0.001 inch). - If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. When using a hone: Coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff nonmetallic rotary brush. Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the caliper with brake fluid; wipe dry with a clean, lintless cloth and then clean a second time. ASSEMBLING CALIPER 1. Clamp caliper in vise (with protector jaws). CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. Installing New Piston Seal In Caliper 2. Dip new piston seal in clean brake fluid and install in groove in bore. Seal should be positioned at one area in groove and gently worked around the groove, using fingers until properly seated. CAUTION: NEVER USE AN OLD PISTON SEAL. (Be sure that fingers are clean and seal is not twisted or rolled). 3. Coat new piston boot with clean brake fluid leaving a generous amount inside of boot. 4. Position dust boot over piston after coating with brake fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5870 Fig. 4 Caliper piston installation 5. Install piston into bore pushing it past the piston seal until it bottoms in the bore. CAUTION: Force must be applied uniformly to avoid cocking the piston. 6. Position dust boot in counterbore. Using a hammer and Tool C4842 with C4171 handle or equivalent, drive boot into counterbore. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5871 Folded Caliper Guide Pin Bushing Guide Pin Sleeve Bushing Installation a. Fold the bushing in half lengthwise at the solid middle section of the bushing. Removing Bushing From Caliper Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5872 Installing Caliper Guide Pin Bushing b. Using your fingers insert the folded bushing into the caliper assembly. Making sure the solid section of the bushing is fully seated into the bushing hole of the caliper assembly. Do not use a sharp object to perform this step due to possible damage to the bushing. Bushing Correctly Installed In Caliper c. Unfold the bushing using your fingers or wooden dowel until the bushing is fully seated into the caliper assembly with the flanges seated evenly on both sides of the bushing holes in the caliper assembly. Fig 7 Installing Caliper Sleeves Guide Pin Sleeve Installation a. Install the sleeve into one end of the bushing until the seal area of the bushing is past the seal groove in the sleeve. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5873 b. Holding the convoluted end of the bushing with one hand. Push the sleeve through the bushing until the one end of the bushing is fully seaated into the seal groove on the one end of the sleeve. Fig 8 Installed Caliper Bushing Sleeve c. Holding the sleeve in place work the other end of the bushing over the end of the sleeve and into the seal groove. Be sure the other end of the bushing did not come out of the seal groove in the sleeve. c. When the sleeve is seated properly into the bushing. The sealed for life bushing can be held between your finger and easily slid back and forth without the bushing seal unseating from the sleeve. NOTE: Before installing caliper assembly on vehicle, inspect braking disc for runout, thickness, and thickness variation. 7. Install caliper assembly. CAUTION: Always use new seal washers when installing brake hose to caliper. 8. Install brake hose to caliper using new seal washers, tighten banjo bolt to 33 Nm (24 ft lb). 9. Bleed the brake system. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes Brake Caliper: Fundamentals and Basics Removal Notes When Removing the Caliper, Remember... - Prior to removing the calipers, remove/siphon brake fluid from master-cylinder until the reservoir is only 1/3 full. - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always replace all brake linings on an axle. Never replace only one wheel. Unequal lining thickness between wheels on the same axle will result in a strong steering pull when the brakes are applied. - Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. - When forcing the piston back into the caliper, open the bleeder valve first. Corrosion and other deposits accumulate inside of the caliper. If the bleeder valve is not opened when the piston is forced back into the caliper, these deposits will be forced back through the brake lines and into the master-cylinder. - When pushing the pistons back into the caliper with the bleeder screw open, a stream of brake fluid will be expelled from the bleeder screw for 2-3 feet. Use a drip pan and be careful not to "shoot" brake fluid onto the vehicle's finish. A cleaner method is to use a piece of clear plastic hose and a glass or plastic jar to catch the expelled fluid. - Upon removal, Do Not allow the calipers to hang by the flexible brake hoses. The brake hoses can be damaged easily by this practice. These hoses are double walled, damage to the interior pressure hose will not be visible. - Do not depress the brake pedal with either caliper removed from the rotor. The caliper pistons will be inadvertently expelled from the caliper. If this occurs rebuild or replace the caliper, do not attempt to insert the piston back into the caliper. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 5876 Brake Caliper: Fundamentals and Basics Installation Notes WHEN INSTALLING CALIPERS AND PADS, REMEMBER... - Clean and lubricate caliper slide joint/pins with high temperature silicone grease: Unlike drum brakes, disc brakes do not utilize a spring to withdraw the pads/linings when the brake pedal is released. Disc brakes rely on the elasticity of the piston seals, and the unrestricted movement of the caliper slide assemblies to release the brakes. If the slide joints/pins are not cleaned and lubricated properly the disc brake linings will drag upon the release of the brake pedal. This will result in overheated brakes and premature brake wear. Disc Brake Mechanical Force Diagram NOTE: Floating calipers require free and unrestricted movement on the caliper mounting. Floating or sliding calipers have pistons only on one side of the rotor. The first part of the piston's travel forces the inner pad against the rotor, then further travel forces the movable part of the caliper to pull the outer pad against the rotor. High temperature silicone lubricant must be used. Low temperature grease can melt and contaminate the pads and rotors, or can bake into a very hard substance which binds the slides. Petroleum based grease can cause the slide boots to soften and swell. - Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. Anti-squeal Coating - Apply an anti-squeal coating to the back side of the pads/linings. This coatings acts as an insulator to dampen high frequency vibrations that are generated during normal braking. These compounds are highly effective in preventing brake squeal. - Many professional repair shops recommend always rebuilding or replacing the calipers when replacing the brake linings, because: When the pistons are forced back into the calipers, the piston seals are dragged across any corrosion or abrasives that may be deposited on the inside of the caliper. Damage to the seals may not be initially evident. As the new brake linings begin to wear, the piston is gradually withdrawn from the caliper. This results in the piston seals again being dragged across the layer of corrosion and deposits. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 5877 Calipers which are not rebuilt or replaced have a higher probability of sticking or leaking. - Check to ensure the bleeder screw is not frozen prior to reinstalling caliper. Freeing a stuck bleeder screw is much easier with the caliper removed from the vehicle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Use new brake fluid only, to top off the master cylinder or refill system. Never use reclaimed fluid, unmarked or unspecified fluid, fluid not meeting SAE/DOT standards, fluid marked 70R1, or fluid from a container that has been left open. Brake Fluid Type DOT 3 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 5881 Brake Fluid: Testing and Inspection Indications of fluid contamination: Swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination: Put small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil contamination. If contaminated: Drain and thoroughly flush system, and replace all rubber parts. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 5882 Brake Fluid: Service and Repair Aluminum Master Cylinder NOTES: - Check master cylinder fluid level twice annually. - Master cylinder reservoirs are marked with the words "fill to bottom of rings". - Add DOT 3 fluid to bring the level to the bottom of the primary split ring. CAUTION: Use of brake fluid with a lower boiling point than DOT 3 fluid could result in brake failure during long, hard braking. CAUTION: Do not use fluid which has been stored in an unsealed container. Brake fluid stored in this manner will absorb moisture which could result in brake failure during long, hard braking. CAUTION: Use of petroleum based fluids will result in seal damage. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation Brake Fluid Pressure Sensor/Switch: Description and Operation The switch activates a light on the dash panel to indicate that one of the hydraulic systems has failed. There are two basic types of switches. In some earlier models, as pressure falls in one system, the normal pressure of the other system forces the piston to the inoperative side where it contacts the switch terminal, causing the warning lights to illuminate. On most models, the brake warning switch is of the latching type. If a pressure loss occurs in one side of the system, the piston in the valve is forced toward the failed side where it latches in position and illuminates the warning light. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Hydraulic brake tubes to all fittings (if not specified) ................................................................................................................................ 17 Nm (143 in lb) Brake hoses to calipers (banjo bolts) ............................................................................................................................................................ 33 Nm (24 ft lb) Brake hose intermediate bracket ............................................................................... .................................................................................... 11 Nm (95 in lb) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 5889 Brake Hose/Line: Service and Repair - Always use factory recommended brake hose to insure quality, correct length and superior fatigue life. - Care should be taken to make sure that the tube and hose mating surfaces are clean and free from nicks and burrs. Right and left hoses are not interchangeable. - Use new copper seal washers on all "banjo" bolts and tighten all fittings to specified torque. Connections should be tight and properly made. - The flexible hydraulic brake hose should always be installed on the vehicle by first attaching the "Banjo" connector to the caliper assembly. Then bolt the intermediate hose bracket to the strut assembly allowing the bracket to position the hose to prevent twisting. Attach the hose to the body bracket and steel brake tubing. Tighten all fittings to specified torque. - The body bracket and hose end are "keyed" so that they will only fit one way. - Install rear brake hoses first to the trailing arm cross member tubes and then to the floor pan tubes. Minimize hose twisting. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Hold-Off Valve Brake Proportioning/Combination Valve: Description and Operation Hold-Off Valve Some vehicles incorporate a hold-off valve, usually in combination with the brake warning switch. This valve holds off hydraulic pressure to the front disc brakes to a given psi range. This allows the rear drum brake shoes to overcome the return springs and begin to contact drums. This action helps prevent locking of the front brakes on icy surfaces under light braking conditions. This valve has no effect on front brake pressure during hard stopping. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Hold-Off Valve > Page 5894 Brake Proportioning/Combination Valve: Description and Operation Proportioning Valve There are two basic types of proportioning valves, one of which is height sensitive. Vehicles may have either one or both of these valves. On the first type, the proportioning valve operates by transmitting full input pressure to the rear brakes up to a certain point, called the split point, then reducing the amount of pressure increase to the rear brakes beyond the split point according to a certain ratio. On light pedal applications, approximately equal brake pressure is transmitted to both front and rear brakes, while at higher pressures, pressure transmitted to rear brakes is lower than that transmitted to front brakes to prevent premature rear wheel lock-up. If hydraulic pressure is lost in front brake system, rear brake system hydraulic pressure moves the brake warning switch piston, opening a bypass in the proportioning valve to allow full rear brake hydraulic pressure. Fig. 1 Typical height sensing proportioning valve The height sensing type of proportioning valve is located under the load bed just forward of the rear axle. This valve automatically provides optimum front-to-rear brake balance regardless of vehicle load. Pressure to the rear brakes is modulated by the proportioning valve sensing vehicle load through relative movement between rear axle and load floor. The valve is mounted to a load floor crossmember. A large external spring is connected between a lever mounted on the valve and an adjustable bracket mounted on the rear axle. Higher brake line pressure is allowed as the load increases. The proportioning valve transmits full input pressure to rear brakes up to a certain point called the split point, and beyond that point reduces the amount of pressure increase to the rear brakes according to a certain ratio, preventing premature wheel lock-up. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 5895 Brake Proportioning/Combination Valve: Testing and Inspection These models use a proportioning valve and pressure differential switch, or a combination valve. When a premature rear wheel skid is obtained during braking, it may be an indication that fluid pressure to rear brakes is above a desired output and/or a malfunction has occurred within the valve. At this time, the valve unit should be tested as follows: Fig. 2 Height Sensing Proportioning Valve Assembly 1. Remove actuator assembly adjustment nut, then disconnect assembly from valve lever and remove. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 5896 Fig. 3 Master Cylinder & Brake Warning Switch 2. Install gauge and Tee from line pressure set No. C-4007, or equivalent, inline with either master cylinder port to the brake valve assembly. 3. Install second gauge from line pressure set No. C-4007, or equivalent, to either rear brake outlet port between valve assembly and rear brake line. Bleed both hydraulic circuits and the gauges. 4. Have an assistant exert pressure on the brake pedal to get a reading on the outlet gauge. Outlet test pressure should read 100-200 psi. 5. Inlet pressure should be 500 psi. If not, replace valve and torque mounting bolts to 250 inch lbs. 6. If both gauges read correctly, reinstall actuator assembly, then adjust and road test vehicle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 5897 Brake Proportioning/Combination Valve: Service and Repair The proportioning valves should never be disassembled. 1. Raise and support vehicle, then access modulator assembly by removing the battery, tray, tray support bracket and acid shield as described under Modulator Assembly/Service and Repair. 2. Disconnect brake tube fitting at proportioning valve, then remove valve from modulator assembly. 3. Reverse procedure to install, noting the following: a. Coat proportioning valve O-ring with clean brake fluid prior to installation. b. Bleed base and anti-lock brake systems separately. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation Hydraulic Control Assembly - Antilock Brakes: Description and Operation This system uses an integral hydraulic assembly which contains the wheel circuit valves used for brake pressure modulation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) Replacement 1. Remove fresh air intake and air cleaner assembly from engine. 2. Remove windshield washer fluid reservoir, then disconnect electrical connectors from hydraulic assembly. 3. Drain as much fluid from hydraulic reservoir as possible. 4. Disconnect pump high pressure line from hydraulic unit. 5. Disconnect pump return hose from steel tube, then cap the end of the steel tube. 6. Disconnect all brakes tubes from hydraulic assembly. 7. Remove retainer clip from brake pedal pin. 8. Remove four hydraulic mounting unit nuts, then the hydraulic unit. 9. Reverse procedure to install, noting the following: a. Torque mounting bolts to 21 ft. lbs. b. Lubricate bearing surface of pedal pin with lubricant. c. Install new retainer clip on pedal pin. d. Torque brake tubes to hydraulic unit to 30 ft. lbs. e. Torque return hose clamp to 10 inch lbs. f. Torque high pressure hose to 12 ft. lbs. g. Bleed brake system as described in this chapter. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 5903 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Modulator Assembly Replacement 1. Raise and support vehicle, then disconnect battery cables at battery. 2. Remove battery hold-down and battery from battery tray, then remove battery tray and Controller Anti-Lock Brake (CAB) from tray support bracket. 3. Loosen battery tray support bracket to modulator assembly mounting bracket bolt, then the battery tray support bracket to frame rail bolt. 4. Lift battery tray support bracket out of vehicle, then remove battery acid shield from ABS modulator assembly. 5. Disconnect six brake tube fittings at modulator assembly, thread savers and proportioning valves, then remove brake tube bundle from modulator assembly. It is not necessary to loosen fittings at junction block. 6. Raise and support vehicle, then disconnect wiring harness 10-way connector at modulator assembly. 7. Remove bolt securing speed control servo to modulator bracket, then position servo aside. 8. Loosen two bolts securing front of modulator bracket to frame rail, then loosen two rear modulator bracket bolts. 9. Lower vehicle, then remove modulator assembly and bracket from vehicle. 10. If necessary, separate modulator assembly from mounting bracket. 11. Reverse procedure to install. Bleed base and anti-lock brake systems separately. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel Brakes > Component Information > Diagrams Height Sensing Proportioning Valve Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel Brakes > Component Information > Diagrams > Page 5907 Load Compensator: Description and Operation Height Sensing Proportioning Valve CAUTION: The use of aftermarket load leveling or capacity increasing devices is prohibited. Use of air shock absorbers or helper springs will cause the valve to inappropriately reduce the rear brake power potentially resulting in increased stopping distance. PURPOSE Proportioning valves balance front to rear braking by controlling at a given ratio, the increase in rear system hydraulic pressure above a preset level. Under light pedal application, the valve allows full hydraulic pressure to the rear brakes. OPERATION These vehicles use a height sensing dual proportioning valve in addition to the regular differential warning switch. This valve is located under the load bed just forward of the rear axle. The height sensing rear brake proportioning valve automatically provides optimum brake balance front-to-rear regardless of the vehicle load condition. The valve modulates the pressure to the rear brakes sensing vehicle load condition through relative movement between the rear axle and the load floor. The valve is mounted to a load floor cross member. A large external spring is connected between a lever mounted on the valve and an adjustable bracket mounted on the rear axle. In conditions of light load the line pressure to the rear brakes is minimized. As the load increases (resulting in decreasing vehicle height) higher brake line pressure is allowed. The proportioning valve section operates by transmitting full input pressure to the rear brakes up to a certain point, called the split point, and beyond that point it reduces the amount of pressure increase to the rear brakes according to a certain ratio. Thus, on light pedal applications, approximately equal brake pressure will be transmitted to the front and rear brakes, while at higher pressures, the pressure transmitted to the rear brakes will be lower than to the front brakes to prevent premature rear wheel lock-up and skid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel Brakes > Component Information > Diagrams > Page 5908 Load Compensator: Testing and Inspection Rear Brakes Locking On Application Height Sensing Proportioning Valve Fig. 3 Master cylinder & brake warning switch. Symptom When a premature rear wheel slide is obtained on brake application, it could be an indication that the fluid pressure to the rear brakes is above the reduction ratio for the rear line pressure and that a malfunction has occurred within the proportioning valve unit which should be tested. To test the proportioning valve, proceed as follows: 1. Disconnect the external spring at the valve end. 2. Install one gauge and "T" of set C4007-A or equivalent in the line from either master cylinder port to the brake valve assembly. 3. Install the second gauge to either rear brake outlet port between proportioning valve assembly and the rear brake line. 4. Bleed both hydraulic circuits and the gauges. 5. Have a helper exert pressure on the brake pedal (holding pressure) to get a reading on the valve inlet gauge and check the reading on the outlet gauge. The inlet pressure should be 500 psi and the outlet pressure should be 100-200 psi. - If not, replace the valve torque mounting bolts to 250 inch lbs. - If the valve tests OK re-adjust external spring and road test vehicle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel Brakes > Component Information > Diagrams > Page 5909 Load Compensator: Adjustments Height Sensing Proportioning Valve NOTE: After installing a new height sensing dual proportioning valve, bleed both hydraulic circuits at rear brakes. CAUTION: The rubber stone/snow shield must be installed when ever the valve is serviced. The shield protects the valve and hydraulic lines from stone impact and the packing of snow and slush. 1. Lift vehicle with a frame contact hoist or other means so that rear suspension is hanging free with shock absorbers disconnected from the axle. 2. Remove tire and wheels from rear axle. 3. Loosen both front spring hanger pivot bolts. NOTE: Ensure rear springs do not contact hoist, or the adjustment will not be correct. 4. Loosen adjustment nut on the actuator assembly. 5. Verify actuator assembly hook is properly seated on valve lever. 6. Pull actuator assembly toward spring hanger until valve lever bottoms on valve body. Hold in position and torque adjustment nut to 25 inch lbs (5 Nm). 7. Install shocks and tire and wheel assemblies, then lower vehicle. 8. With full weight on vehicles wheels, torque both front spring hanger pivot bolts to 95 ft lb (129 Nm). 9. Road test vehicle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Hydraulic brake tubes to all fittings (if not specified) ................................................................................................................................ 17 Nm (143 in lb) Master cylinder to brake booster mounting nuts ......................................................................................................................................... 28 Nm (250 in lb) Brake booster assembly to dash panel ........................................................................................................................................................ 28 Nm (250 in lb) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 5913 Brake Master Cylinder: Service Precautions CAUTION: Do not hone the bore of the cylinder as this will remove the anodized surface. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 5914 Brake Master Cylinder: Description and Operation Aluminum Master Cylinder CAUTION: Do not hone the bore of the cylinder as this will remove the anodized surface. OPERATION The brake system is a diagonally split system. This system operates on the same principles as conventional front and rear split systems using primary and secondary master cylinders moving simultaneously to exert hydraulic pressure on their respective systems. The hydraulic brake lines on this system, however, have been diagonally split front to rear (left front to right rear and right front to left rear) in place of separate lines to the front and rear wheels. System Failure In the event of a system failure this would cause the remaining good system to do all the braking on one front wheel and the opposite rear wheel, thus maintaining 50% of the total braking force. The hydraulic pressure loss would result in a pressure differential in the system and cause a warning light on the dashboard to glow as in front and rear split systems. CONSTRUCTION The tandem master cylinder has a glass reinforced nylon reservoir and an anodized aluminum body. The secondary outlet tube from the master cylinder is connected to the valve mounted under the master cylinder. The front part of this block supplies the right rear and left front brakes. - The rear portion of the block connects to the primary outlet tube and supplies the right front and left rear brakes. The reservoir is indexed to prevent installation in the wrong direction. The cap diaphragms are slit to allow pressure to equalize. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 5915 Brake Master Cylinder: Testing and Inspection INSPECTION Inspect for Leakage NOTE: The master-cylinder should be cleaned thoroughly prior to inspection (several days preferably). Spilled brake fluid can be easily confused with leakage. Piston Seals Leakage around the piston seals will seep out from the end of the cylinder and leak down the outside of the brake booster. - Inspect for signs of seepage or bubbled paint on the brake booster. - If any leakage is detected the master-cylinder should be replaced or overhauled Brake Line Fittings While someone is applying pressure to the brake pedal, inspect the brake line fittings on the master-cylinder for leakage. - If the fittings are leaking they should be disassembled and inspected. Reservoir to Cylinder Gasket Inspect the gasket for signs of leakage or hardening and cracking. Overhaul or replace the master-cylinder if any leakage is indicated. Inspect for Oil Contamination. - Inspect the rubber gasket on the inside of the master-cylinder lid. If the gasket is swollen or bloated, the brake fluid is contaminated with oil. - Siphon or scoop a small amount of brake fluid out of the master-cylinder and place into a styrofoam cup filled 2/3 of the way with water. Brake fluid will mix with the water while oil contaminants will float on the surface and dissolve the styrofoam. NOTE: If any oil contamination is present ALL brake components containing rubber seals will need to be replaced or overhauled. This includes the master-cylinder, both front calipers, both rear wheel cylinders, and all flexible brake hoses. Verify Hold-Down Bolts Are Tight - While someone is applying and releasing pressure to the brake pedal, verify the the master-cylinder is tightly secured to the brake booster. Retighten hold-down bolts if necessary. Functional Checks WARNING: Always bleed the entire brake system and verify the rear brakes are properly adjusted prior to diagnosing a master-cylinder as defective. For additional information on master-cylinder / brake pedal relationship see Fundamentals and Basics. See: Fundamentals and Basics Check Related Systems Check for proper brake booster operation 1. With the engine "OFF", depress and release the brake pedal 4-5 times (this bleeds off the vacuum reserve in the booster). 2. Depress the brake pedal firmly and start the engine. If the pedal goes down slightly the brake booster is assisting in brake operation. If the pedal does not go down slightly the brake booster is not assisting in brake operation and should be diagnosed for problems. - Check and adjust rear brakes. - Check all brake lines and brake assemblies for leakage. Repair all deficiencies with related systems prior to diagnosing the master-cylinder as defective. Check Brake Pedal Travel (Non-Antilock Brake Systems Only) Fully depress the brake pedal and check for the following: The pedal should have a 75% reserve. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 5916 Pedal Reserve Checks - The pedal should be firm and not leak down. Prior to replacing a master-cylinder for poor pedal travel or feel verify the following: There were no problems with any of the related systems. - The entire brake system has been bled. - Rear brakes are properly adjusted. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 5917 Brake Master Cylinder: Adjustments Not adjustable Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Brake Master Cylinder: Service and Repair Master Cylinder Bleeding Bench Bleeding Bleeding Master Cylinder NOTE: It is not necessary to bleed the entire hydraulic system after replacing the master cylinder if the master cylinder has been bench bled and refilled prior to installation. 1. Clamp master cylinder in vise and attach bleeding tubes. 2. Use residual valve on outlet of each bleeder tube. 3. Fill both reservoirs with approved brake fluid. 4. Depress push rod slowly and then allow pistons to return. 5. Repeat several times until all air bubbles are expelled. 6. Remove bleeding tubes from cylinder, plug outlets and install caps. 7. Remove from vise and install master cylinder. For additional information see Bench Bleeding Notes. See: Fundamentals and Basics Manual Bleeding 1. On models with anti-lock brakes, turn ignition switch to Off position, then pump brake pedal a minimum of 40 times to de-pressurize hydraulic accumulator. 2. On all models, connect a suitable transparent hose to bleeder valve on right rear wheel cylinder and submerge other end in a glass container partially filled with clean brake fluid. 3. Pump brake pedal several times, then hold pedal down firmly. 4. With pedal firmly depressed, open bleeder valve of right rear brake until pedal fades to floor, then close bleeder valve. 5. Repeat procedure until a continuous flow of brake fluid is released from bleeder valve. Ensure a fluid level is maintained in master cylinder at all times. 6. Perform Steps 2 through 5 for left rear, right front, and left front brakes in that order. 7. After bleeding of brakes is completed, road test vehicle to ensure brakes are operating correctly and pedal is solid. Pressure Bleeding Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5920 Air Trapped In Brake System NOTE: When bleeding the brake system some air may be trapped in the brake line or valving far upstream, sometimes as much as ten feet from the bleeder screw. Therefore it is absolutely essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure the system is purged of all air bubbles. Bleeding Brake System Caliper Bleeding Screw CAUTION: Pressure bleed system using equipment designed for this purpose and vehicle only. 1. Wipe master cylinder caps and top with a clean rag. 2. Connect pressure bleeder following manufacturer's instructions for use of bleeder. 3. Attach a clear plastic hose to the bleeder screw at one wheel and insert the other end of the tube into a clear jar containing fresh brake fluid. 4. Open the bleeder screw at least one full turn. CAUTION: "Cracking" the bleeder screw often allows only a slow weak fluid flow. This may not be sufficient to remove all air from the system. 5. After a good volume of fluid has been forced through the brake system, an "air free flow" in the plastic hose and clear jar indicates a thorough bleed. 6. Repeat this procedure at all other bleeder screws. 7. Check brake pedal travel. If pedal travel is excessive repeat the procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5921 Brake Master Cylinder: Service and Repair Master Cylinder Replacement Removal Master Cylinder 1. Disconnect primary and secondary brake tubes from master cylinder and install plugs at outlets. 2. Remove nuts attaching master cylinder to power brake booster. 3. Slide master cylinder straight out, away from power brake booster. For additional information see Notes, Warnings, and Hints. See: Fundamentals and Basics Installation Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5922 Master Cylinder 1. Position master cylinder over studs of power brake booster. 2. Align push rod with master cylinder piston. 3. Install attaching nuts and tighten to specification 22.6-34 Nm (200-300 in lb). 4. Connect brake tubes and have a helper apply force to the brake pedal while tube nuts are cracked to release any air, then tighten to specification 13-20 Nm (115-170 in lb). For additional information see Notes, Warnings, and Hints. See: Fundamentals and Basics Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5923 Brake Master Cylinder: Service and Repair Master Cylinder Overhaul Aluminum Master Cylinder CAUTION: Do not hone the bore of the cylinder as this will remove the anodized surface. If the cylinder is scored, replace the master cylinder as an assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5924 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement Removing Reservoir 1. Clean housing and reservoir. 2. Remove caps and empty brake fluid. 3. Position master cylinder in vise. 4. Rock reservoir from side to side and remove from master cylinder housing. CAUTION: Do not pry off with tool as this may damage reservoir. Removing Grommets 5. Remove housing to reservoir grommets. 6. Install new housing to reservoir grommets in master cylinder housing. 7. Lubricate reservoir mounting area with brake fluid. 8. Place reservoir in position over grommets and seat reservoir with a rocking motion onto master cylinder housing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Page 5925 Brake Master Cylinder: Tools and Equipment BASIC SERVICE (Removal and Installation) - Fender cover (servicing and bleeding a master-cylinder can be a messy process) WARNING: DOT 3 or 4 brake fluid is very corrosive to the vehicles finish and electrical connections. - Drip pan. - Complete set of combination wrenches or sockets. - Bleeding device: - Pressure bleeder or - Vacuum bleeder or - One-man brake bleeder kit or - Length of clear plastic hose (3/16 inch ID) and a glass jar. Brake Bleeding Setup - Brake adjusting tool (rear brake adjustment should be checked) - Clean shop towels. OPTIONAL - Master Cylinder bleeding kit (contains plastic fittings and hoses used for bleeding master cylinders) - Suction bulb (for removing brake fluid from reservoir) IF MASTER-CYLINDER IS OVERHAULED - Snap-ring pliers - Small pry bar (for separating the reservoir from the cylinder) - Feeler gauges (for checking piston to cylinder clearance). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints Brake Master Cylinder: Fundamentals and Basics Notes, Warnings, and Hints REMOVAL WARNING: DOT 3 or DOT 4 brake fluid is very corrosive to your vehicles finish. Removing master cylinders can be a messy process. To prevent or minimize any possible damage perform the following: Siphon all brake fluid from the master-cylinder reservoir prior to removal. - Use a fender cover to protect the vehicles finish. - Use a drip pan to catch all fluid that leaks from the master-cylinder during removal. - Any brake fluid which contacts the vehicles finish should be washed off immediately. - Any brake fluid which drips onto electrical connections should be immediately removed (aerosol brake cleaner works well for this). After the brake lines have been disconnected from the master-cylinder place vacuum caps over ends of the lines to prevent further leakage or contamination. Once the master-cylinder has been removed place it in a drip pan. Although the reservoir is empty, brake fluid trapped within the cylinder bore will continue to slowly leak out. OVERHAUL WARNING: Never hone aluminum cylinders, if deposits cannot be removed with crocus cloth the cylinder should be replaced. Check the cylinder bore for excessive clearance. With the piston installed you should not be able to install a 0.006 inch feeler gauge between piston and cylinder. If the clearance is greater than 0.006 inches the cylinder should be replaced. When installing the piston and seals into the cylinder always use clean brake fluid or assembly lubricant to lubricate the components. INSTALLATION Prior to installation the master-cylinder should be bench bled (this can be done on the vehicle but it is much easier on a workbench. NOTE: Normal brake bleeding procedures will not remove air which is trapped in the cylinder bore area of a master-cylinder. Attach the brake line fittings prior to snugging down the master-cylinder retaining bolts. The fittings are much easier to start turning when the master-cylinder is still loose. WARNING: Remember to tighten the retaining bolts after the brake lines are installed and tightened. When snugging down the retaining bolts, alternately tighten them in small increments. This prevents the master-cylinder or push rod from becoming cocked. Upon installing the master-cylinder the entire brake system (front and rear) will need to be bled. Air enters the brake system as soon as the brake lines are removed. It only requires a very small amount of air in the system to create a soft brake pedal. WARNING: Never test drive a vehicle after a master-cylinder replacement until a firm brake pedal with a 75% reserve is established. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 5928 Brake Master Cylinder: Fundamentals and Basics Parts Reminder List RECOMMENDED PARTS Basic Service, Replacement New or rebuilt master-cylinder - Fresh/New brake fluid If Overhaul is Required Master cylinder overhaul kit - Brake assembly lubricant Optional Aerosol brake cleaner. New or Rebuilt Master Cylinder Always closely compare the new master-cylinder with the old master-cylinder. Minor variations in the size and depth of the primary piston can result in significant reductions in braking performance. Examine the end of the master-cylinder where the pushrod contacts the piston. The depth and diameters of the pistons should match. Brake Fluid - Proper bench bleeding the master-cylinder and flushing the brake system will require a minimum of 16 oz of brake fluid. - Never Mix DOT 3 (light amber in color) with DOT 5 (purple in color). There have been reports of damage to brake system seals when DOT 3 and DOT 5 fluids are mixed - Always store brake fluid in a sealed container. When left open brake fluid will absorb moisture from the air. This reduces the boiling point of the brake fluid and could lead to a soft pedal or brake system failure during prolonged or emergency braking. - Never add automatic transmission fluid, engine oil, or power steering fluid to the master-cylinder. Petroleum based fluids will cause the rubber seals and gaskets in the brake system to swell and leak. Master Cylinder Overhaul Kit Overhaul kits will often come with a variety cup and seal sizes. Closely match the old cups and seals with the new ones. Brake Assembly Lubricant Assembly lubricant can greatly simply the master-cylinder overhaul process and prolong the life of the new seals. - Clean brake fluid can be used to lubricate the master-cylinder bore during assembly but assembly lube is much slicker and prevents any sticking or binding and possible damage to the new cups and seals. Aerosol Brake Cleaner - Commercially produced aerosol brake cleaners are designed to effectively clean brake systems while not leaving an oily residue. - Do not use carburetor cleaner or solvent based products to clean brake system components. These products will leave a residue which could contaminate the brake fluid or cause a reduction in braking performance. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 5929 Brake Master Cylinder: Fundamentals and Basics Master Cylinder / Brake Pedal Relationship MASTER CYLINDER / BRAKE PEDAL RELATIONSHIP WARNING: Master Cylinders can be easily misdiagnosed for problems related to excessive brake pedal travel. Excessive brake pedal travel is often associated with a defective master-cylinder, however total pedal travel is affected by a wide variety of components and issues. Issues Affecting Pedal Travel Brake Fluid Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 5930 - Brake fluid which is contaminated with air or water will significantly add to the amount of pedal travel. - Pure DOT 3 (or 4) brake fluid is incompressible (allowing for a solid, firm pedal). A small amount of air trapped in the brake fluid will require extra effort from the master-cylinder to compress it, resulting in a soft and spongy pedal. - During prolonged or severe braking the brake fluid temperature can rapidly rise above 212 degrees F. When this occurs any water in the brake fluid will boil into steam (which is compressable) and create a soft and spongy pedal. Rear Brake Shoe Adjustment Drum brake system utilize return springs to pull the shoes away from the drums when not in use. The amount of distance the shoes have to extend to meet the drums greatly affects the amount of pedal travel. - Shoes/Linings which are badly out of adjustment can by themselves result in a brake pedal sinking all the way to the floor NOTE: Improperly adjusted rear shoes/linings also affect the parking brake. Calipers Excessive rotor wobble caused by a warped rotor or loose/worn wheel bearings can knock the caliper piston further inward from its normal resting position. This results in additional pedal travel required to extend the piston and apply the brakes. Drum Expansion Drums which are worn past their "Discard" thickness are prone to expanding outwards into an oval shape during heavy braking. This drum expansion results in additional brake pedal travel. Brake Fade During prolonged or severe braking, the amount of pedal effort/travel required to slow the vehicle increases as the ability of the brakes to dissipate heat decreases. - As the brake linings heat up, their "coefficient of friction" is reduced (they become slicker). As the coefficient of friction is reduced, more hydraulic pressure is required to stop the vehicle. More hydraulic pressure results in more heat which then results in more pedal fade. - As the brake linings, rotors, and drums begin to wear, their ability to absorb and release heat is reduced significantly. This makes worn brakes more prone to "pedal fade". NOTE: Prior to replacing a master-cylinder, verify the entire brake system is functioning properly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 5931 Brake Master Cylinder: Fundamentals and Basics Bench Bleeding Notes BENCH BLEEDING Why A master-cylinder will develop little or no pressure if air is trapped in cylinder bore. Normal brake bleeding will not remove air trapped within the master-cylinder. How Clamp the master-cylinder securely in a vice. It is usually best to clamp the side of the vice onto the flat surface that is used to secure the master-cylinder to the brake booster. There are two basic methods for bleeding master-cylinder, one utilizes stroking the master-cylinder to expel air from the cylinder bore while the other utilizes a large syringe to backflush fluid from the outlet ports to the reservoir. Stroking Fill the master-cylinder with clean brake fluid. - The brake line fittings on the master-cylinder should be capped or plugged. NOTE: Special "bench bleeding" plastic fittings are available which allow for recirculating the brake fluid back into the reservoir. - Using a dull object, slowly stroke the master-cylinder piston, air and brake fluid will be expelled from the brake line fittings. Prior to releasing the piston plug or cap the outlet ports. - Repeat this procedure 8-10 times or until no air is emitted from the outlet ports. - When finished, cap the outlet ports and install the master-cylinder. Syringe Fill the syringe (one especially designed for brake bleeding) with clean brake fluid. - Insert the end of the syringe into one of the outlet ports on the master-cylinder. - Slowly compress the syringe and back flush the brake fluid through the master-cylinder. - A combination of air and brake fluid will be emitted from the inlet port in the fluid reservoir. - Repeat this procedure until only brake fluid is emitted into the reservoir. - Cap the outlet ports and install the master-cylinder. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Bore Diameter Wheel Cylinder: Specifications Rear Wheel Cylinder Bore Diameter 0.75 in Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Bore Diameter > Page 5936 Wheel Cylinder: Specifications Wheel Cylinder To Support Plate 6 ft.lb Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Page 5937 Fig 3 Wheel Cylinder Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal Wheel Cylinder: Service and Repair Wheel Cylinder Removal Fig 1 Brake Tube Disconnected 1. In case of a leak, remove brake shoes, (replace if soaked with grease or brake fluid). 2. Disconnect brake tube from wheel cylinder. Fig 2 Removing Or Installing Wheel Cylinder 3. Remove wheel cylinder attaching bolts, then pull wheel cylinder assembly out of support. For additional information see Notes, Warnings, and Hints. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 5940 Wheel Cylinder: Service and Repair Wheel Cylinder Installation For additional information see Notes, Warinings, and Hints. Brake Shoe Contact Pads On Backing (Support) Plate 1. Apply RTV sealant around wheel cylinder mounting surface. Fig 2 Removing Or Installing Wheel Cylinder Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 5941 Fig 1 Brake Tube Disconnected 2. Slide wheel cylinder into position on support. Install mounting screws and tighten as specified. 3. Connect brake tube to wheel cylinder. 4. Insert parking brake cable into support plate and attach cable to parking brake lever. 5. Install brake shoes on support plate. 6. Install brake drum and wheel. 7. Adjust and bleed brakes. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 5942 Wheel Cylinder: Service and Repair Cleaning and Inspection Fig 3 Wheel Cylinder 1. With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. 2. Block brake pedal in stroke position, visually check the boots for cuts, tears, or heat cracks. If any of the above conditions exist, the wheel cylinders should be completely cleaned, inspected and new parts installed. NOTE: A slight amount of fluid on the boot may be preservative fluid used at assembly and should not automatically be considered a leak. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 5943 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul For additional information see Notes, Warinings, and Hints. Fig 3 Wheel Cylinder NOTE: To perform service operations or inspections of the wheel cylinders, it will be necessary to remove the cylinders from the support plate and disassemble on the bench. CAUTION: Wheel cylinders with cup expanders must have cup expanders after any service procedures (reconditioning or replacement). DISASSEMBLING WHEEL CYLINDERS 1. Pry boots away from cylinders and remove. 2. Press In on one piston to force out other piston, cup, spring -- with cup expanders -- cup and piston. 3. Wash wheel cylinder, pistons, and spring in clean brake fluid or alcohol. - Clean thoroughly and blow dry with compressed air. CAUTION: Do not use a rag as lint from the rag will adhere to bore surfaces. 4. Inspect cylinder bore and piston for scoring and pitting. - Wheel cylinder bores and pistons that are badly scored or pitted should be replaced. - Cylinder walls that have light scratches, or show signs of corrosion, can usually be cleaned with crocus cloth, using a circular motion. - Black stains on the cylinder walls are caused by piston cups and will not impair operation of cylinder. ASSEMBLING WHEEL CYLINDERS Assembly Notes: Before assembling the pistons and new cups in the wheel cylinders, dip them in clean brake fluid. - If the boots are deteriorated, cracked or do not fit tightly on the push rods or the cylinder casting, install new boots. 1. Coat cylinder bore with clean brake fluid. 2. Install expansion spring with cup expanders in cylinder. Install cups in each end of cylinder with open end of cups facing each other. 3. Install piston in each end of cylinder having the flat face of each piston contacting the flat face of each cup, already installed. 4. Install a boot over each end of cylinder. Use care not to damage boot. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Diagrams Parking Brake Cable Routing Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Diagrams > Page 5948 Parking Brake Cable: Testing and Inspection Inspect parking brake cable ends, inspect cables for kinks, fraying and elongation, and replace as necessary. TIP: Use a small hose clamp to compress clamp where it enters backing plate to remove. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement Parking Brake Cable: Service and Repair Front Cable Replacement FRONT PARKING BRAKE CABLE Remove Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 5951 Parking Brake Cable Routing FWD & AWD Removing Brake Cable From Brake Support Plate 1. Loosen cable adjusting nut and disengage front cable from adjuster. Remove cable housing retainer from anchor bracket, by sliding a 14 mm box wrench over cable retainer and compressing the three fingers. Alternate method is to use an aircraft type hose clamp and screwdriver. This is similar to the method shown for removing the parking brake cable from the support plate. 2. Remove cable guide brackets from frame rail and loosen cable housing at pedal assembly. 3. Lift floor mat for access to floor pan and force seal out of hole (into vehicle). 4. Pull park brake cable strand end forward and disconnect button from clevis. Tap cable housing end fitting out of pedal assembly bracket. 5. Pull park brake cable assembly into vehicle through hole in floor pan. Install Parking Brake Removal And Install 1. Pass cable assembly through hole in floor from inside vehicle. 2. Install cable retainer into brake pedal assembly bracket and then install cable housing end fitting into retainer. 3. Engage cable strand button into clevis. 4. Install floor pan seal and floor mat. 5. Insert brake cable and housing into anchor bracket making certain that housing retainer fingers lock the housing firmly into place. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 5952 6. Install cable guide brackets. 7. Assemble adjuster to front cable. 8. Adjust parking brake. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 5953 Parking Brake Cable: Service and Repair Rear Cable Replacement REAR PARKING BRAKE CABLE Remove Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 5954 Parking Brake Cable Routing FWD & AWD 1. With vehicle jacked up on suitable hoist remove wheel and tire. 2. Back off cable adjusting nut to provide slack and disconnect rear cable from equalizer bracket. Removing Brake Cable From Brake Support Plate 3. To remove cable from anchor bracket. Remove cable housing retainer from anchor bracket by sliding a 14 mm box wrench over retainer end compressing the three fingers. Alternate method is to use an aircraft type hose clamp and screwdriver. This is similar to the method shown for removing the brake cable from the brake support plate. 4. Remove cable wrap-around clips where applicable. 5. Disconnect cable guide wires where applicable. 6. Remove brake drum and hub from spindle 7. Disconnect cable from brake internal lever. 8. Remove park brake cable housing retainer from the brake support plate. Use the same method for removing cable retainer from brake support plate as was used above for the cable anchor bracket. Install 1. Insert park brake cable into hole in the brake support plate. Attach park brake cable to park brake internal lever attached to brake shoe. 2. Insert cable housing retainer into brake support plate making certain that cable housing retainer fingers lock the housing and retainer firmly into place. 3. Install brake drum, wheel and tire. 4. Insert cable housing retainer into anchor bracket making certain that cable housing retainer fingers lock the housing firmly into place. 5. Attach cable guide wires and wrap-around clips where applicable. 6. Connect equalizer bracket. 7. Adjust service brakes and then adjust parking brake. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Master cylinder to brake booster mounting nuts ......................................................................................................................................... 28 Nm (250 in lb) Brake booster assembly to dash panel ........................................................................................................................................................ 28 Nm (250 in lb) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake Booster > Component Information > Description and Operation > Vacuum Booster Description Vacuum Brake Booster: Description and Operation Vacuum Booster Description These units are self contained vacuum hydraulic power braking units. They are the vacuum suspended type which use engine intake manifold vacuum and atmospheric pressure for their power, eliminating the need for a vacuum reservoir. A mechanically operated control valve, integral with the vacuum power diaphragms, controls degree of brake application or release depending on amount of foot pressure applied to valve operating rod through the brake pedal linkage. The control valve is a single poppet type valve with the atmospheric port and a vacuum port. The vacuum port seal is a part of the valve body attached to the diaphragm assembly. The atmospheric port is a part of the valve plunger which moves within the valve housing and vacuum power diaphragm assembly. These units require no maintenance and must be replaced as a complete assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake Booster > Component Information > Description and Operation > Vacuum Booster Description > Page 5961 Vacuum Brake Booster: Description and Operation Vacuum Booster Operation These units are self contained vacuum hydraulic power braking units. They are the vacuum suspended type which use engine intake manifold vacuum and atmospheric pressure for their power, eliminating the need for a vacuum reservoir. A mechanically operated control valve, integral with the vacuum power diaphragms, controls degree of brake application or release depending on amount of foot pressure applied to valve operating rod through the brake pedal linkage. The control valve is a single poppet type valve with the atmospheric port and a vacuum port. The vacuum port seal is a part of the valve body attached to the diaphragm assembly. The atmospheric port is a part of the valve plunger which moves within the valve housing and vacuum power diaphragm assembly. These units require no maintenance and must be replaced as a complete assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Unit Service Vacuum Brake Booster: Service and Repair Power Brake Unit Service The only serviceable power brake booster components are the vacuum hose and the check valve. NOTE: The power brake booster must be serviced as an assembly. If diagnosis indicates a power brake booster fault, the unit must be replaced as an assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Unit Service > Page 5964 Vacuum Brake Booster: Service and Repair Vacuum Booster Replacement 1. Remove master cylinder attaching nuts, slide master cylinder from mounting studs and support on fender shield. Do not disconnect brake tubes from master cylinder. 2. Disconnect vacuum hose from power brake unit. Do not remove check valve from booster. 3. Install suitable screwdriver between center tang on retainer clip and brake pedal pin located under instrument panel. Rotate screwdriver so retainer clip center tang will pass over brake pedal pin. 4. Pull retainer clip from pin and discard clip. 5. Remove brackets from steel heater water line at dash panel and left frame rail, if equipped. 6. On models equipped with manual transaxle, remove clutch cable bracket at shock tower and position aside. 7. On all models, remove power brake unit attaching nuts, then the power brake unit from vehicle. 8. Reverse procedure to install, ensuring to use retainer new clip. Do not attempt to service booster, it can only be serviced by replacing assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations Fig. 19 Engine Compartment Wiring Mounted on left fender side shield. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 5969 ABS Main Relay: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect wiring harness electrical connectors from relays, then remove screw securing relay assembly to left front inner fender. 3. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Locations Brake Fluid Pump Relay: Locations Fig. 19 Engine Compartment Wiring Mounted on left fender side shield. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams ABS Module Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 5976 Electronic Brake Control Module: Description and Operation The Controller Anti-Lock Brake (CAB) is located on the front lefthand side of the engine compartment. The CAB uses the information from the wheel speed sensors to control the anti-lock brake system function. The CAB also monitors ABS operation and detects system faults. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 5977 Electronic Brake Control Module: Service and Repair 1. With ignition switch in Off position, disconnect both battery cables and remove battery, then remove battery tray from vehicle. 2. Remove Controller Anti-lock Brake (CAB) from battery tray support bracket. 3. Loosen bolt securing 60-way connector to CAB, then disconnect connector from CAB by pulling straight out. Do not twist connector. 4. Remove CAB with its mounting bracket from vehicle. 5. Reverse procedure to install, noting the following: a. Ensure ignition switch is still in Off position before connecting 60-way connector to CAB. b. Torque connector bolt to 38 inch lbs. and CAB assembly mounting bolt to 14 inch lbs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation Brake Fluid Pressure Sensor/Switch: Description and Operation The switch activates a light on the dash panel to indicate that one of the hydraulic systems has failed. There are two basic types of switches. In some earlier models, as pressure falls in one system, the normal pressure of the other system forces the piston to the inoperative side where it contacts the switch terminal, causing the warning lights to illuminate. On most models, the brake warning switch is of the latching type. If a pressure loss occurs in one side of the system, the piston in the valve is forced toward the failed side where it latches in position and illuminates the warning light. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: All Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5990 39 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5991 43 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5992 45 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5993 47 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5994 51 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5995 55 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5996 57 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5997 59 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5998 63 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5999 67 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6000 69 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6001 71 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6002 173 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6003 177 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6004 179 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6005 181 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6006 187 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6007 191 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6008 193 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6009 195 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6010 201 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6011 205 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6012 207 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6013 209 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6014 256 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously Wheel Speed Sensor: All Technical Service Bulletins ABS - Warning Light ON Continuously NO: 05-22-94 GROUP: Brakes EFFECTIVE DATE: Dec. 2, 1994 SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor Connector MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) SYMPTOM/CONDITION: Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles brake system will perform as a non-ABS equipped vehicle normally would during this condition. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair as necessary. If an ABS wheel speed sensor DTC is discovered: 1. Disconnect the 2 way connector of the suspect wheel speed sensor. 2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body harness connector. There should be resistance/interference felt between the male and female terminals. 3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic Procedures for further diagnostics. 4. If no resistance/interference is felt at one or both terminals, perform the repair procedure. PARTS REQUIRED: 1 4797997 Kit, Terminal Repair Kit Consists Of: 1 4625196 Terminal, Male 1 Connector/Wire Assembly 2 4778570 Tube, Heat Shrink REPAIR PROCEDURE: This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread female terminals. 1. Cut off the suspect body harness connector and discard. 2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and the new connector/wire assembly. 3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and spread the strands of the wire. 4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands together with the strands prepared in step 3 and twist together. 5. Solder the wires together with ROSIN core solder. 6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 7. Repeat steps 3 - 6 for the other wires. 8. Connect the body harness to the wheel speed sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously > Page 6019 9. Test drive the vehicle and verify proper operation of the ABS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-18-97 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 050694 > Apr > 94 > Antilock Brake System - Wheel Speed Sensor Diagnosis Wheel Speed Sensor: All Technical Service Bulletins Antilock Brake System - Wheel Speed Sensor Diagnosis NO: 05-06-94 GROUP: Brakes DATE: Apr. 1, 1994 SUBJECT: Bendix Antilock-4 Wheel Speed Sensor Diagnosis MODELS: 1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1994 (AP) Shadow/Shadow Convertible/Sundance 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH BENDIX ANTILOCK-4 ABS. DISCUSSION: Bendix Antilock-4 ABS wheel speed sensors that have been returned under warranty for inspection have been and are continuing to be tested. An unusually large number of these wheel speed sensors are being found to have no defects. The following steps must be followed when diagnosing Bendix Antilock-4 ABS equipped vehicles: The diagnostic manual MUST be followed without exception. No shortcuts should be used during the diagnostic procedure. All diagnostic work Must begin with test "1A". All diagnostic work MUST end with "VER-1A". Following the above steps will ensure correct diagnosis of Bendix Antilock-4 ABS issues as well as preventing an unnecessary increase in Expense Per Unit Repaired (EPUR) for your dealership. POLICY: Information only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 051793A > Dec > 93 > ABS - Wheel Speed Sensor Applications Wheel Speed Sensor: All Technical Service Bulletins ABS - Wheel Speed Sensor Applications NO.: 05-17-93 Rev. A GROUP: Brakes DATE: Dec. 22, 1993 SUBJECT: Left Front Wheel Speed Sensor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-17-93 DATED NOV. 12, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1991-1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN ANTILOCK BRAKE SYSTEM (ABS). DISCUSSION: On the vehicles listed above, there are two wheel speed sensors specified for the left front wheel, depending upon the model year. The difference between the two parts is the length of the wiring, and they should not be interchanged. P/N 4683057 has longer wiring and must be used only on **1993 and** 1994 model vehicles. If this part is used on prior model year vehicles the wiring may become damaged. P/N 4509213 must be used only on 1991 ** and 1992 ** model vehicles. If this part is used on a ** later ** model vehicle, the wiring is too short and would have to be routed improperly to connect to the vehicle wiring harness. This may cause damage to the wheel speed sensor wiring. This bulletin supersedes any information in the Mopar Parts Catalog or PAIS at this time. A parts catalog bulletin is being developed and the parts catalog will be revised at a later date. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 052294 > Dec > 94 > ABS Warning Light ON Continuously Wheel Speed Sensor: Customer Interest ABS - Warning Light ON Continuously NO: 05-22-94 GROUP: Brakes EFFECTIVE DATE: Dec. 2, 1994 SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor Connector MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) SYMPTOM/CONDITION: Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles brake system will perform as a non-ABS equipped vehicle normally would during this condition. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair as necessary. If an ABS wheel speed sensor DTC is discovered: 1. Disconnect the 2 way connector of the suspect wheel speed sensor. 2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body harness connector. There should be resistance/interference felt between the male and female terminals. 3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic Procedures for further diagnostics. 4. If no resistance/interference is felt at one or both terminals, perform the repair procedure. PARTS REQUIRED: 1 4797997 Kit, Terminal Repair Kit Consists Of: 1 4625196 Terminal, Male 1 Connector/Wire Assembly 2 4778570 Tube, Heat Shrink REPAIR PROCEDURE: This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread female terminals. 1. Cut off the suspect body harness connector and discard. 2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and the new connector/wire assembly. 3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and spread the strands of the wire. 4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands together with the strands prepared in step 3 and twist together. 5. Solder the wires together with ROSIN core solder. 6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 7. Repeat steps 3 - 6 for the other wires. 8. Connect the body harness to the wheel speed sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 052294 > Dec > 94 > ABS Warning Light ON Continuously > Page 6033 9. Test drive the vehicle and verify proper operation of the ABS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-18-97 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: All Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6039 39 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6040 43 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6041 45 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6042 47 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6043 51 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6044 55 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6045 57 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6046 59 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6047 63 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6048 67 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6049 69 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6050 71 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6051 173 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6052 177 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6053 179 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6054 181 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6055 187 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6056 191 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6057 193 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6058 195 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6059 201 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6060 205 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6061 207 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6062 209 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 26-10-99I > Oct > 99 > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 6063 256 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 050694 > Apr > 94 > Antilock Brake System - Wheel Speed Sensor Diagnosis Wheel Speed Sensor: All Technical Service Bulletins Antilock Brake System - Wheel Speed Sensor Diagnosis NO: 05-06-94 GROUP: Brakes DATE: Apr. 1, 1994 SUBJECT: Bendix Antilock-4 Wheel Speed Sensor Diagnosis MODELS: 1993 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1994 (AP) Shadow/Shadow Convertible/Sundance 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH BENDIX ANTILOCK-4 ABS. DISCUSSION: Bendix Antilock-4 ABS wheel speed sensors that have been returned under warranty for inspection have been and are continuing to be tested. An unusually large number of these wheel speed sensors are being found to have no defects. The following steps must be followed when diagnosing Bendix Antilock-4 ABS equipped vehicles: The diagnostic manual MUST be followed without exception. No shortcuts should be used during the diagnostic procedure. All diagnostic work Must begin with test "1A". All diagnostic work MUST end with "VER-1A". Following the above steps will ensure correct diagnosis of Bendix Antilock-4 ABS issues as well as preventing an unnecessary increase in Expense Per Unit Repaired (EPUR) for your dealership. POLICY: Information only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 051793A > Dec > 93 > ABS - Wheel Speed Sensor Applications Wheel Speed Sensor: All Technical Service Bulletins ABS - Wheel Speed Sensor Applications NO.: 05-17-93 Rev. A GROUP: Brakes DATE: Dec. 22, 1993 SUBJECT: Left Front Wheel Speed Sensor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-17-93 DATED NOV. 12, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1991-1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN ANTILOCK BRAKE SYSTEM (ABS). DISCUSSION: On the vehicles listed above, there are two wheel speed sensors specified for the left front wheel, depending upon the model year. The difference between the two parts is the length of the wiring, and they should not be interchanged. P/N 4683057 has longer wiring and must be used only on **1993 and** 1994 model vehicles. If this part is used on prior model year vehicles the wiring may become damaged. P/N 4509213 must be used only on 1991 ** and 1992 ** model vehicles. If this part is used on a ** later ** model vehicle, the wiring is too short and would have to be routed improperly to connect to the vehicle wiring harness. This may cause damage to the wheel speed sensor wiring. This bulletin supersedes any information in the Mopar Parts Catalog or PAIS at this time. A parts catalog bulletin is being developed and the parts catalog will be revised at a later date. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 6072 Wheel Speed Sensor: Description and Operation The wheel speed sensors are located at each wheel and transmit wheel speed information to the Controller Anti-Lock Brake (CAB). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front 1. Raise and support vehicle, then remove wheel and tire assembly. Fig. 252 Front Wheel Speed Sensor Assembly 2. Remove screw from clip that retains sensor wiring grommet, then pull sensor grommet from fenderwell. 3. Disconnect electrical connector, then remove two screws retaining sensor wiring routing tube. 4. Remove sensor head screw, then the sensor head from steering knuckle. NOTE: If sensor head is seized, use a punch and gently rock sensor back and forth until free. Do not use pliers on sensor head. 5. Reverse procedure to install. Coat sensor with suitable high temperature E.P. grease and torque mounting bolt to 5 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 6075 Wheel Speed Sensor: Service and Repair Rear 1. Raise and support vehicle, then remove wheel and tire assembly. 2. Remove sensor wiring grommet retainer bracket, then pull sensor grommet from underbody. 3. Disconnect electrical connector, then remove wiring to frame rail attaching bracket. 4. Remove rear axle U-bolt nuts, then the sensor assembly mounting bracket. 5. Remove sensor head screw, then the sensor head from steering knuckle. If sensor head is seized, use a punch and gently rock sensor back and forth until free. Do not use pliers on sensor head. 6 Reverse procedure to install, noting the following: a. Torque sensor mounting bolt to 5 ft. lbs. b. Torque U-bolt nuts to 65 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection Bosch & Nippondenso Starters The clutch pedal switch is a normally open type switch. 1. Locate and disconnect clutch pedal switch connector. 2. Using a suitable continuity tester, check circuit through switch with pedal released, there should be no continuity. 3. With continuity tester still attached, push clutch pedal to floor, tester should show full continuity. 4. Tester should not show continuity until pedal is fully depressed, replace switch if it fails any test. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition - Tamper Resistant Ignition Cylinder Addition NUMBER: 23-44-94D GROUP: Body DATE: Jun. 3, 1994 Models: 1994 Town & Country, Caravan, Voyager - Publication No. 81-370-4105 DISCUSSION: A new method of ignition key cylinder retention is used on the subject vehicles for improved vehicle security. The ignition key cylinder retaining pin has been replaced with a tamper resistant screw and a bracket, refer to the illustration. A Snap-On TTXR20A2 torx-bit or equivalent is required to remove the screw. The 1995 Dakota service manual was completed prior to this information being available to Service Publications. The vehicles listed as 1994 models only, will have this information already in their corresponding 1995 service manual. DESCRIPTION OF CHANGES Add Tamper Resistant Ignition Key Cylinder Info. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 6086 8D - 37 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 6087 8D - 38 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 6088 8D - 39 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 6089 8D - 39A Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Customer Interest: > 210294 > Feb > 94 > A/T - Engine Stalls On Takeoff Neutral Safety Switch: Customer Interest A/T - Engine Stalls On Takeoff NO: 21-02-94 GROUP: Transmission DATE: Feb. 18, 1994 SUBJECT: Engine Stalls Following Initial Shift From Park Or Neutral To A Forward Gear MODELS: 1991 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1991 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1991 - 1993 (AG) Daytona 1991 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1992 1993 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1993 (AS) Town & Country/Caravan/Voyager 1991 - 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 41TE TRANSMISSIONS. IN ADDITION TO THE VEHICLES LISTED ABOVE, ANY 1989 - 1990 41TE EQUIPPED VEHICLES THAT HAVE HAD A REPLACEMENT CONTROLLER INSTALLED THAT HAS COOLING FINS, OR IS LABELED WITH P/N 4672104, 4672105, 4672209, OR 4713832 ARE ALSO INCLUDED. SYMPTOM/CONDITION: While the temperature of the transmission is -16 F (-27 C) or colder, and the transmission selector lever is placed in any forward gear position, the engine stalls. This can be the result of ice in the neutral/start switch while the Transmission Control Module (TCM) performs the pump prime test when the transmission temperature is -16 F (-27 C) or colder. DIAGNOSIS: Determine if the ambient temperature could have been -16 F (-27 C) or colder when the transmission lever was placed in a forward gear position. Assure the shift selector is not binding and is adjusted correctly. Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB) with appropriate diagnostic procedure manual, verify that all transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707123 Switch, Neutral/Start (Park/Neutral) REPAIR PROCEDURE: NOTE: THE SWITCH SEAL WASHER MUST BE PROPERLY SEATED WHEN TIGHTENING THE SWITCH. FAILURE TO DO SO MAY RESULT IN LEAKAGE OF TRANSMISSION FLUID. This bulletin involves replacing the park/neutral position switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Customer Interest: > 210294 > Feb > 94 > A/T - Engine Stalls On Takeoff > Page 6098 1. Replace the black park/neutral position switch (P/N 5234319). Torque the new switch to 25 ft.lbs. (34 N-m). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-57-90........0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 210294 > Feb > 94 > A/T - Engine Stalls On Takeoff Neutral Safety Switch: All Technical Service Bulletins A/T - Engine Stalls On Takeoff NO: 21-02-94 GROUP: Transmission DATE: Feb. 18, 1994 SUBJECT: Engine Stalls Following Initial Shift From Park Or Neutral To A Forward Gear MODELS: 1991 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1991 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1991 - 1993 (AG) Daytona 1991 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1992 1993 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1993 (AS) Town & Country/Caravan/Voyager 1991 - 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 41TE TRANSMISSIONS. IN ADDITION TO THE VEHICLES LISTED ABOVE, ANY 1989 - 1990 41TE EQUIPPED VEHICLES THAT HAVE HAD A REPLACEMENT CONTROLLER INSTALLED THAT HAS COOLING FINS, OR IS LABELED WITH P/N 4672104, 4672105, 4672209, OR 4713832 ARE ALSO INCLUDED. SYMPTOM/CONDITION: While the temperature of the transmission is -16 F (-27 C) or colder, and the transmission selector lever is placed in any forward gear position, the engine stalls. This can be the result of ice in the neutral/start switch while the Transmission Control Module (TCM) performs the pump prime test when the transmission temperature is -16 F (-27 C) or colder. DIAGNOSIS: Determine if the ambient temperature could have been -16 F (-27 C) or colder when the transmission lever was placed in a forward gear position. Assure the shift selector is not binding and is adjusted correctly. Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB) with appropriate diagnostic procedure manual, verify that all transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707123 Switch, Neutral/Start (Park/Neutral) REPAIR PROCEDURE: NOTE: THE SWITCH SEAL WASHER MUST BE PROPERLY SEATED WHEN TIGHTENING THE SWITCH. FAILURE TO DO SO MAY RESULT IN LEAKAGE OF TRANSMISSION FLUID. This bulletin involves replacing the park/neutral position switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 210294 > Feb > 94 > A/T - Engine Stalls On Takeoff > Page 6104 1. Replace the black park/neutral position switch (P/N 5234319). Torque the new switch to 25 ft.lbs. (34 N-m). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-57-90........0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Neutral Safety Switch: > 212493 > Sep > 93 > M/T - Vent Oil Leak Case: All Technical Service Bulletins M/T - Vent Oil Leak NO.: 21-24-93 GROUP: Transmission DATE: Sep. 3, 1993 SUBJECT: Oil Leak At Transaxle Vent MODELS: 1990 - 1993 (AG) Daytona 1990 - 1994 (AA) Spirit/Acclaim (AJ) LeBaron Coupe/LeBaron Convertible (AP) Shadow/Shadow Convertible/Sundance (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH MANUAL TRANSAXLE MODELS A-523, A-543, OR A-568. SYMPTOM/CONDITION: Transaxle oil leak on or around selector shaft cover and/or other surrounding surfaces, including the rear end cover and differential bearing retainer. Oil found to be leaking out of vent cap on crossover lever. NOTE: THIS REPAIR SHOULD BE PREFORMED ON ALL VEHICLES WITH A VENT LEAK. CUSTOMER VEHICLES THAT ARE IN THE DEALERSHIP FOR ANY OTHER REASON SHOULD ALSO BE INSPECTED FOR THIS LEAK CONDITION. PARTS REQUIRED: 1 Vent Adapter 4762499 1 Vent 4505557 REPAIR PROCEDURE: This bulletin involves installing a remote vent assembly in place of the existing lock pin. Also included is a new linkage adjusting procedure if needed for future transaxle service. 1. Clean any excess oil from surrounding surfaces. 2. Remove, lock pin located on transaxle selector shaft cover (Figure 1). Discard lock pin. 3. Install vent adapter (P/N 4762499) in selector shaft cover where lock pin was removed. Tighten to 40 in.lbs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Neutral Safety Switch: > 212493 > Sep > 93 > M/T - Vent Oil Leak > Page 6110 4. Install vent (P/N 4505557) into vent adaptor (P/N 4762499) and tighten to 35 in. lbs. NOTE: IF FOR ANY REASON THE SHIFT LINKAGE REQUIRES ADJUSTMENT, THE FOLLOWING PROCEDURE IS PROVIDED AND DOES NOT REQUIRE THE USE OF A LOCK PIN. 1. Gain access to the transaxle crossover cable adjusting screw located at the floor shifter in the vehicle interior as outlined in the appropriate service manual. 2. Loosen the adjusting screw to allow the crossover cable adjustment fitting to slide freely (Figure 2). 3. Shift the transaxle into 4th gear then into 3rd gear and then back into 4th gear. Leave gearshift lever in the 4th gear position and tighten crossover cable adjusting screw to 70 in.lbs. CAUTION: DO NOT LEAN ON OR APPLY A LOAD TO THE SHIFT LEVER WHEN TIGHTENING THE ADJUSTING SCREW. 4. Reinstall all hardware removed in Step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 21-35-36-93 0.3 Hrs. FAILURE CODE: 71 - Oil Leak Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Neutral Safety Switch: > 212493 > Sep > 93 > M/T - Vent Oil Leak > Page 6116 4. Install vent (P/N 4505557) into vent adaptor (P/N 4762499) and tighten to 35 in. lbs. NOTE: IF FOR ANY REASON THE SHIFT LINKAGE REQUIRES ADJUSTMENT, THE FOLLOWING PROCEDURE IS PROVIDED AND DOES NOT REQUIRE THE USE OF A LOCK PIN. 1. Gain access to the transaxle crossover cable adjusting screw located at the floor shifter in the vehicle interior as outlined in the appropriate service manual. 2. Loosen the adjusting screw to allow the crossover cable adjustment fitting to slide freely (Figure 2). 3. Shift the transaxle into 4th gear then into 3rd gear and then back into 4th gear. Leave gearshift lever in the 4th gear position and tighten crossover cable adjusting screw to 70 in.lbs. CAUTION: DO NOT LEAN ON OR APPLY A LOAD TO THE SHIFT LEVER WHEN TIGHTENING THE ADJUSTING SCREW. 4. Reinstall all hardware removed in Step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 21-35-36-93 0.3 Hrs. FAILURE CODE: 71 - Oil Leak Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Page 6117 Neutral Safety Switch: Locations Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions Neutral Safety Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6120 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6121 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6122 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6123 Neutral Safety Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Page 6124 Neutral Safety Switch: Description and Operation The Neutral Safety Switch sends a signal to the EATX control module and the engine control module, controlling starter relay operation when the transaxle is in any gear other than Park or Neutral. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Page 6125 Neutral Safety Switch: Testing and Inspection The 4 speed Automatic Transaxle is computer controlled, if troubleshooting this system, extract codes. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Page 6126 Neutral Safety Switch: Service and Repair Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 6131 In Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 6132 Starter Relay: Testing and Inspection Fig 4 Starter Relay Tests 1. Remove starter relay from relay center. 2. Perform testing procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service Bulletins > Customer Interest for Battery Cable: > 085394 > Oct > 94 > Engine Starter - Intermittent No Crank Battery Cable: Customer Interest Engine Starter - Intermittent No Crank NO: 08-53-94 GROUP: Electrical DATE: Oct. 7, 1994 SUBJECT: Intermittent No Crank MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Engine intermittently will not crank. DIAGNOSIS: Inspect the battery to starter cable connection at the starter (Refer to Illustration). If the terminal is not fully seated, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves modifying the battery to starter cable terminal insulator at the starter connection. 1. Record the customers preset radio station selections. 2. Disconnect the ground cable from the battery. 3. Remove the battery to starter cable from the starter. 4. Grind off hard plastic material 1/8 - 5/16 in. (3 - 5 mm) as shown in the illustration. 5. Place battery to starter cable on the starter. Make sure the terminal seats flat as shown in the illustration. If the terminal does not seat flush, grind off more plastic until the terminal can seat flush. 6. Connect the battery to starter cable to the starter. Torque the nut to 75 in.lbs. (9 N-m). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service Bulletins > Customer Interest for Battery Cable: > 085394 > Oct > 94 > Engine Starter - Intermittent No Crank > Page 6142 7. Connect the ground cable to the battery. 8. Reprogram the customers preset radio stations and set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-12-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Battery Cable: > 085394 > Oct > 94 > Engine Starter - Intermittent No Crank Battery Cable: All Technical Service Bulletins Engine Starter - Intermittent No Crank NO: 08-53-94 GROUP: Electrical DATE: Oct. 7, 1994 SUBJECT: Intermittent No Crank MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Engine intermittently will not crank. DIAGNOSIS: Inspect the battery to starter cable connection at the starter (Refer to Illustration). If the terminal is not fully seated, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves modifying the battery to starter cable terminal insulator at the starter connection. 1. Record the customers preset radio station selections. 2. Disconnect the ground cable from the battery. 3. Remove the battery to starter cable from the starter. 4. Grind off hard plastic material 1/8 - 5/16 in. (3 - 5 mm) as shown in the illustration. 5. Place battery to starter cable on the starter. Make sure the terminal seats flat as shown in the illustration. If the terminal does not seat flush, grind off more plastic until the terminal can seat flush. 6. Connect the battery to starter cable to the starter. Torque the nut to 75 in.lbs. (9 N-m). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Battery Cable: > 085394 > Oct > 94 > Engine Starter - Intermittent No Crank > Page 6148 7. Connect the ground cable to the battery. 8. Reprogram the customers preset radio stations and set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-12-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications Generator: Specifications Alternator ID. ....................................................................................................................................................... Output Amps @ 15 Volts, 1250 RPM 4557431 [02] ........................................................................................................................................ ..................................................................... 84 [01] 5234031 ............................................................. ........................................................................................................................................................ 86 [01] 5234032 ........................................................................................................................................ ............................................................................. 90 [01] 5234208 ..................................................... .............................................................................................................................................................. .. 98 [01] 5234033 ................................................................................................................................ ................................................................................... 102 [01] Footnotes: [01] -- Minimum. [02] -- Bosch alternator. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions Generator: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6155 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6156 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6157 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6158 Generator: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6159 Generator: Connector Views Generator Connections Generator Connections Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6160 Generator Field Circuit Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Page 6161 Generator: Application and ID ID No. .................................................................................................................................................. .................................................... 5234032, 5234033 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Page 6162 Generator: Description and Operation The main components of the alternator are the rotor, stator, rectifier, end shields and drive pulley. Direct current is available at the output "B+" terminal. Alternator output is controlled by voltage regulator circuitry contained within the power and logic modules of the Engine Controller. The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced. As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. Once the generator begins producing sufficient current, it also provides the current needed to energize the rotor. The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified DC current is delivered to the vehicle electrical system through the generator, battery, and ground terminals. Noise emitting from the generator may be caused by: Worn, loose or defective bearings - Loose or defective drive pulley - Incorrect, worn, damaged or misadjusted drive belt - Loose mounting bolts - Misaligned drive pulley - Defective stator or diode Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes Generator: Reading and Clearing Diagnostic Trouble Codes Displaying & Reading Trouble Codes CHECK ENGINE LAMP To start the function, cycle ignition switch ON-OFF-ON-OFF-ON within 5 seconds and any stored fault code will appear. Check engine lamp will display the code by flashing on and off. There is a short pause between flashes and a longer pause between digits. All codes displayed are 2 digit numbers with a 4 second pause between codes. The lamp will flash until all codes are displayed then 55 (end test) will appear. SCAN TOOL 1. On 1994-95 models, connect DRB test tool or equivalent scan tool, to Diagnostic Link Connector (DCL) located under the hood. 2. On 1996 models, connect DRB test tool or equivalent scan tool, to DCL located under the instrument panel. 3. On all models, follow scan tool manufactures instructions to access Diagnostic Trouble Codes (DTCs). Clearing Diagnostic Trouble Codes Diagnostic Trouble Codes (DTCs) may only be cleared with the use of a suitable scan tool. Follow scan tool manufacturers instructions to clear DTCs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 6165 Generator: Component Tests and General Diagnostics Troubleshooting Fig 1 Charging System Diagnosis Chart Alternator Output Wire Resistance Test TEST PROCEDURE 1. Disconnect battery ground cable. 2. Disconnect "B+" lead at alternator output terminal. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 6166 Fig 2 Alternator Output Wire Resistance Test Fig 3 Alternator Output Wire Resistance Test 3. Connect a 0-150 amp D.C. ammeter in series between alternator "B+" terminal and disconnected "B+" lead wire. 4. Connect positive lead wire of a suitable voltmeter to disconnected "B+" lead wire, then connect negative lead to battery positive post. 5. Remove air hose between Engine Controller and air cleaner. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 6167 Fig. 4 Alternator Connections (Plug Type) Fig. 5 Alternator Connections (Nut Type) 6. Connect suitable jumper wire to ground and K20 (field driver) terminal at rear of alternator. This may generate a fault code. Do not connect powered field circuit to ground, as component damage will occur. 7. Connect a suitable engine tachometer, then reconnect battery ground cable. 8. Ensure carbon pile is in OPEN or OFF position, then connect a variable carbon pile rheostat to battery terminals. 9. Start engine and operate at idle speed, then adjust carbon pile and engine speed to maintain a 20 amp circuit flow. Note voltmeter reading. Voltmeter reading should not exceed 0.5 volt. TEST RESULTS 1. If a higher than specified voltage drop is indicated, clean and tighten all connectors in charging circuit. A voltage drop inspection may be performed at each connector to locate point of excessive resistance. 2. If charging circuit resistance inspection was satisfactory, disconnect battery ground cable, then the ammeter, voltmeter, carbon pile and tachometer. 3. Remove jumper wire. 4. Connect battery ground cable, then the hose between Engine Controller and air cleaner. 5. Erase codes using DRB inspection tool or equivalent scan tool. Output Current Test TEST PROCEDURE 1. Disconnect battery ground cable. 2. Disconnect "B+" lead at alternator output terminal. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 6168 Fig 6 Alternator Current Output Test Fig 7 Alternator Current Output Test 3. Connect a 0-150 amp D.C. ammeter in series between alternator "B+" terminal and disconnected "B+" lead wire. 4. Connect positive lead of a suitable voltmeter to "B+" terminal of alternator, then connect negative lead to suitable ground. 5. Connect a suitable engine tachometer, then reconnect battery ground cable. 6. Connect a variable carbon pile rheostat between battery terminals, ensuring carbon pile is in Open or Off position. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 6169 7. Remove air hose between Engine Controller and air cleaner. Fig. 4 Alternator Connections (Plug Type) Fig. 5 Alternator Connections (Nut Type) 8. Connect suitable jumper wire to ground and K20 (field driver) terminal, at rear of alternator. This may generate a fault code. Do not connect power field circuit to ground, as component damage will occur. 9. Start engine and operate at idle speed, then adjust carbon pile and engine speed in increments until a speed of 1250 RPM at 15 volts is obtained. Do not allow voltmeter range to exceed 16 volts during inspection. TEST RESULTS 1. Note ammeter reading. 2. If reading is less than specified and alternator wire resistance is not excessive, alternator is defective. 3. After completion of current output inspection, turn off carbon pile and ignition switch, then disconnect battery ground cable. 4. Remove ammeter, voltmeter, tachometer and carbon pile, then reconnect "B+" lead to alternator output terminal. 5. Disconnect jumper wire, then connect air hose from Engine Controller to air cleaner. 6. Connect battery ground cable. 7. On models quipped with on board diagnostics, erase codes using DRB test tool or equivalent scan tool. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Page 6170 Generator: Service and Repair Fig. 5 Alternator Replacement 1. Disconnect battery ground cable and remove alternator drive belt. 2. Loosen but do not remove nut on alternator support bracket at exhaust manifold. 3. Remove alternator/tensioner/power steering bracket bolt, then the tensioner stud nut and tensioner. 4. Remove alternator mounting bolts, then the power steering reservoir from alternator mounting bracket and position aside. Do not remove power steering hoses from reservoir. 5. Remove three alternator support bracket bolts, then the intake plenum to alternator mounting bracket bolt. 6. Remove alternator support bracket, then the alternator electrical wiring. 7. Remove alternator from vehicle. 8. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection Bosch & Nippondenso Starters The clutch pedal switch is a normally open type switch. 1. Locate and disconnect clutch pedal switch connector. 2. Using a suitable continuity tester, check circuit through switch with pedal released, there should be no continuity. 3. With continuity tester still attached, push clutch pedal to floor, tester should show full continuity. 4. Tester should not show continuity until pedal is fully depressed, replace switch if it fails any test. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Tamper Resistant Ignition Key Cylinder - Revision Ignition Lock: Technical Service Bulletins Tamper Resistant Ignition Key Cylinder - Revision NO: 23-44-94 GROUP: Body DATE: Jun. 3, 1994 SUBJECT: Service Manual Correction Tamper Resistant Ignition Key Cylinder MODELS: 1994 (AA) Spirit/Acclaim/LeBaron Sedan (Built after 3/16/94 MDH 0316XX) 1994 (AB) Ram Van/Wagon (Built after 3/10/94 MDH 0310XX) 1994 (AJ) LeBaron Convertible (Built after 3/16/94 MDH 0316XX) 1994 - 1995 (AN) Dakota/Dakota Cab & Chassis (Built after 3/14/94 MDH 0314XX) 1994 (AS) Caravan/Voyager/Town & Country (Built after 3/28/94 MDH 0328XX) 1994 (BR) Ram Pickup (Built after 3/14/94 MDH 0314XX) 1994 (ZJ) Grand Cherokee (Built after 3/10/94 MDH 0310XX) DISCUSSION: A new method of ignition key cylinder retention is used on the subject vehicles for improved vehicle security. The ignition key cylinder retaining pin has been replaced with a tamper resistant screw and a bracket, refer to the illustration. A Snap-On TTXR2OA2 torx-bit or equivalent is required to remove the screw. The 1995 Dakota service manual was completed prior to this information being available to Service Publications. The vehicles listed as 1994 models only, will have this information already in their corresponding 1995 service manual. This technical service bulletin contains revised service manual pages. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Tamper Resistant Ignition Key Cylinder - Revision > Page 6179 Please insert the revised service manual pages in the appropriate service manual. NOTE: THE REVISION PAGES ARE REDUCED IN SIZE TO ACCOMMODATE PLACEMENT OVER THE EXISTING PAGE. TWO SIDED TAPE IS ALSO APPLIED TO MAKE INSERTION INTO THE MANUAL PERMANENT. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition - Tamper Resistant Ignition Cylinder Addition NUMBER: 23-44-94D GROUP: Body DATE: Jun. 3, 1994 Models: 1994 Town & Country, Caravan, Voyager - Publication No. 81-370-4105 DISCUSSION: A new method of ignition key cylinder retention is used on the subject vehicles for improved vehicle security. The ignition key cylinder retaining pin has been replaced with a tamper resistant screw and a bracket, refer to the illustration. A Snap-On TTXR20A2 torx-bit or equivalent is required to remove the screw. The 1995 Dakota service manual was completed prior to this information being available to Service Publications. The vehicles listed as 1994 models only, will have this information already in their corresponding 1995 service manual. DESCRIPTION OF CHANGES Add Tamper Resistant Ignition Key Cylinder Info. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 6185 8D - 37 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 6186 8D - 38 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 6187 8D - 39 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition - Tamper Resistant Ignition Cylinder Addition > Page 6188 8D - 39A Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > Customer Interest for Neutral Safety Switch: > 210294 > Feb > 94 > A/T - Engine Stalls On Takeoff Neutral Safety Switch: Customer Interest A/T - Engine Stalls On Takeoff NO: 21-02-94 GROUP: Transmission DATE: Feb. 18, 1994 SUBJECT: Engine Stalls Following Initial Shift From Park Or Neutral To A Forward Gear MODELS: 1991 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1991 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1991 - 1993 (AG) Daytona 1991 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1992 1993 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1993 (AS) Town & Country/Caravan/Voyager 1991 - 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 41TE TRANSMISSIONS. IN ADDITION TO THE VEHICLES LISTED ABOVE, ANY 1989 - 1990 41TE EQUIPPED VEHICLES THAT HAVE HAD A REPLACEMENT CONTROLLER INSTALLED THAT HAS COOLING FINS, OR IS LABELED WITH P/N 4672104, 4672105, 4672209, OR 4713832 ARE ALSO INCLUDED. SYMPTOM/CONDITION: While the temperature of the transmission is -16 F (-27 C) or colder, and the transmission selector lever is placed in any forward gear position, the engine stalls. This can be the result of ice in the neutral/start switch while the Transmission Control Module (TCM) performs the pump prime test when the transmission temperature is -16 F (-27 C) or colder. DIAGNOSIS: Determine if the ambient temperature could have been -16 F (-27 C) or colder when the transmission lever was placed in a forward gear position. Assure the shift selector is not binding and is adjusted correctly. Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB) with appropriate diagnostic procedure manual, verify that all transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707123 Switch, Neutral/Start (Park/Neutral) REPAIR PROCEDURE: NOTE: THE SWITCH SEAL WASHER MUST BE PROPERLY SEATED WHEN TIGHTENING THE SWITCH. FAILURE TO DO SO MAY RESULT IN LEAKAGE OF TRANSMISSION FLUID. This bulletin involves replacing the park/neutral position switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > Customer Interest for Neutral Safety Switch: > 210294 > Feb > 94 > A/T - Engine Stalls On Takeoff > Page 6197 1. Replace the black park/neutral position switch (P/N 5234319). Torque the new switch to 25 ft.lbs. (34 N-m). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-57-90........0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 210294 > Feb > 94 > A/T - Engine Stalls On Takeoff Neutral Safety Switch: All Technical Service Bulletins A/T - Engine Stalls On Takeoff NO: 21-02-94 GROUP: Transmission DATE: Feb. 18, 1994 SUBJECT: Engine Stalls Following Initial Shift From Park Or Neutral To A Forward Gear MODELS: 1991 - 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1991 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1991 - 1993 (AG) Daytona 1991 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1992 1993 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1993 (AS) Town & Country/Caravan/Voyager 1991 - 1993 (AY) Imperial/New Yorker Fifth Avenue NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH 41TE TRANSMISSIONS. IN ADDITION TO THE VEHICLES LISTED ABOVE, ANY 1989 - 1990 41TE EQUIPPED VEHICLES THAT HAVE HAD A REPLACEMENT CONTROLLER INSTALLED THAT HAS COOLING FINS, OR IS LABELED WITH P/N 4672104, 4672105, 4672209, OR 4713832 ARE ALSO INCLUDED. SYMPTOM/CONDITION: While the temperature of the transmission is -16 F (-27 C) or colder, and the transmission selector lever is placed in any forward gear position, the engine stalls. This can be the result of ice in the neutral/start switch while the Transmission Control Module (TCM) performs the pump prime test when the transmission temperature is -16 F (-27 C) or colder. DIAGNOSIS: Determine if the ambient temperature could have been -16 F (-27 C) or colder when the transmission lever was placed in a forward gear position. Assure the shift selector is not binding and is adjusted correctly. Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB) with appropriate diagnostic procedure manual, verify that all transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If no codes are present and all systems are functioning correctly, proceed with the following repair. PARTS REQUIRED: 1 4707123 Switch, Neutral/Start (Park/Neutral) REPAIR PROCEDURE: NOTE: THE SWITCH SEAL WASHER MUST BE PROPERLY SEATED WHEN TIGHTENING THE SWITCH. FAILURE TO DO SO MAY RESULT IN LEAKAGE OF TRANSMISSION FLUID. This bulletin involves replacing the park/neutral position switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 210294 > Feb > 94 > A/T - Engine Stalls On Takeoff > Page 6203 1. Replace the black park/neutral position switch (P/N 5234319). Torque the new switch to 25 ft.lbs. (34 N-m). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-57-90........0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > Page 6204 Neutral Safety Switch: Locations Sound Cover Installed PRNDL Switch This applies to the 4 speed electronic automatic transaxle. The torque for the PRNDL switch is 34 Nm (25 ft. lbs.). The thread size is M22 X 2.5 Neutral Safety Switch The torque for the Neutral Safety Switch is 34 Nm (25 ft. lbs.). The thread size is 3/4 inch X 16 Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions Neutral Safety Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6207 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6208 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6209 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6210 Neutral Safety Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Page 6211 Neutral Safety Switch: Description and Operation The Neutral Safety Switch sends a signal to the EATX control module and the engine control module, controlling starter relay operation when the transaxle is in any gear other than Park or Neutral. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Page 6212 Neutral Safety Switch: Testing and Inspection The 4 speed Automatic Transaxle is computer controlled, if troubleshooting this system, extract codes. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Page 6213 Neutral Safety Switch: Service and Repair Transmission Range Switch This applies to the 4 speed electronic automatic transaxle. The torque for the white Transmission Range Switch (formerly called PRNDL) is 34 Nm (25 ft. lbs.). Park/Neutral Position Switch The torque for the black Park/Neutral Position Switch (formerly called Neutral Safety Switch) is 34 Nm (25 ft. lbs.). Caution: Switch Seal washer must be seated properly before tightening switch. Failure to do so may result in leakage of transmission fluid. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Customer Interest for Starter Motor: > 085394 > Oct > 94 > Engine Starter - Intermittent No Crank Starter Motor: Customer Interest Engine Starter - Intermittent No Crank NO: 08-53-94 GROUP: Electrical DATE: Oct. 7, 1994 SUBJECT: Intermittent No Crank MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Engine intermittently will not crank. DIAGNOSIS: Inspect the battery to starter cable connection at the starter (Refer to Illustration). If the terminal is not fully seated, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves modifying the battery to starter cable terminal insulator at the starter connection. 1. Record the customers preset radio station selections. 2. Disconnect the ground cable from the battery. 3. Remove the battery to starter cable from the starter. 4. Grind off hard plastic material 1/8 - 5/16 in. (3 - 5 mm) as shown in the illustration. 5. Place battery to starter cable on the starter. Make sure the terminal seats flat as shown in the illustration. If the terminal does not seat flush, grind off more plastic until the terminal can seat flush. 6. Connect the battery to starter cable to the starter. Torque the nut to 75 in.lbs. (9 N-m). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Customer Interest for Starter Motor: > 085394 > Oct > 94 > Engine Starter - Intermittent No Crank > Page 6222 7. Connect the ground cable to the battery. 8. Reprogram the customers preset radio stations and set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-12-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Motor: > 085394 > Oct > 94 > Engine Starter - Intermittent No Crank Starter Motor: All Technical Service Bulletins Engine Starter - Intermittent No Crank NO: 08-53-94 GROUP: Electrical DATE: Oct. 7, 1994 SUBJECT: Intermittent No Crank MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Engine intermittently will not crank. DIAGNOSIS: Inspect the battery to starter cable connection at the starter (Refer to Illustration). If the terminal is not fully seated, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves modifying the battery to starter cable terminal insulator at the starter connection. 1. Record the customers preset radio station selections. 2. Disconnect the ground cable from the battery. 3. Remove the battery to starter cable from the starter. 4. Grind off hard plastic material 1/8 - 5/16 in. (3 - 5 mm) as shown in the illustration. 5. Place battery to starter cable on the starter. Make sure the terminal seats flat as shown in the illustration. If the terminal does not seat flush, grind off more plastic until the terminal can seat flush. 6. Connect the battery to starter cable to the starter. Torque the nut to 75 in.lbs. (9 N-m). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Motor: > 085394 > Oct > 94 > Engine Starter - Intermittent No Crank > Page 6228 7. Connect the ground cable to the battery. 8. Reprogram the customers preset radio stations and set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-12-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Page 6229 Starter Motor: Specifications Torque - Starter Mounting Bolts ............................................................................................................................................................ 54 N.m (40 ft. lbs.) - Starter Solenoid Battery Nut ................................................................................................................................................... 10 N.m (90 in. lbs.) Make .................................................................................................................................................... ............................................................. Nippondenso ID. No. ............................................................. .............................................................................................................................................................. ...... -- Type .......................................................................................................................................... .................................................................... Gear Reduction Power Rating, Kw ................................. .............................................................................................................................................................. .............. 1.2 Free Speed Test Amps [01] ............................................................................................................................................ .................................................................... 73 Volts ........................................................................... .............................................................................................................................................. 11 RPM [02] ....................................................................................................................................................... ...................................................... 3401 Cranking Amp Draw Test [03] ............................................................................................................. .................................................................... 150-200 No of fields ........................................................................................................................................... ............................................................................... 4 No of Poles ....................................................... .............................................................................................................................................................. ...... 4 Brushes ..................................................................................................................................... ............................................................................................ 4 Drive .................................................... ........................................................................................................................................... Conventional Gear Train Footnotes: [01] -- Maximum. [02] -- Minimum. [03] -- With engine at operating temperature. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Page 6230 Starter Motor: Application and ID Make .................................................................................................................................................... ............................................................. Nippondenso ID. No. ............................................................. .............................................................................................................................................................. ...... -- Type .......................................................................................................................................... .................................................................... Gear Reduction Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Page 6231 Starter Motor: Description and Operation The Nippondenso starters are reduction gear field coil units; Bosch permanent magnet reduction gear starters contain a planetary gear train which transmits power between the starter motor and its pinion shaft. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Troubleshooting Starter Motor: Testing and Inspection Troubleshooting Fig 1 Starter Motor Troubleshooting Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Troubleshooting > Page 6234 Fig 2 Starting System Components Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Troubleshooting > Page 6235 Starter Motor: Testing and Inspection Diagnosis and Testing Starter Feed Circuit Tests 1. Disable ignition system on gasoline engines or fuel system on diesel engines. 2. Connect volt/ampere tester to battery terminals. Refer to operating instructions provided with tester being used. 3. Verify that all lights and accessories are Off and transmission shift selector is in Park for automatic transmissions/transaxles or Neutral for manual transmissions/transaxles, then set parking brake. 4. Hold ignition switch in Start position. Observe tester. a. If voltage reads above 9.6 volts and amperage draw reads above 250 amps, proceed to starter feed circuit resistance test. b. If voltage reads 12.4 volts or greater and amperage reads 0-10 amps, proceed to starter control circuit test. c. If starter motor turns engine freely at times, but starting system is still suspected, engage starter several times while observing tester. A starting system that has a problem should fail while performing this procedure. 5. After starting system problem have been corrected, verify battery state of charge, disconnect all testing equipment and connect distributor. Starter Feed Circuit Resistance Test The following test will require a voltmeter accurate to 0.1 volt. 1. Disable ignition system on gasoline engines or fuel system on diesel engines. 2. With all wiring harness and components connected properly, perform the following: a. Connect positive lead of voltmeter to battery negative post, and negative lead to battery negative cable clamp. Rotate and hold ignition switch in Start position. Observe voltmeter. If voltage is not detected, correct poor contact between cable clamp and post. b. Connect positive lead of voltmeter to battery positive post, and negative lead to battery cable positive clamp. Rotate and hold ignition switch in Start position. Observe voltmeter. If voltage is not detected, correct poor contact between cable clamp and post. c. Connect positive lead of voltmeter to battery negative terminal, and negative led to engine block near battery cable attaching point. 3. Rotate and hold ignition switch in Start position. If voltage reads above 0.2 volt, correct poor contact at ground cable attaching point. If reading is still above 0.2 volt, replace ground cable. 4. Remove starter heat shield (if equipped), then perform the following: a. Connect positive voltmeter lead to starter motor housing and negative lead to battery negative terminal. Rotate and hold ignition switch in Start position. If voltage reads above 0.2 volt, correct poor starter to engine ground. b. Connect positive voltmeter lead to positive battery terminal and negative lead to battery cable terminal on starter solenoid. Rotate and hold ignition switch in Start position. If voltage reads above 0.2 volt, correct poor contact at battery cable to solenoid connection. If reading is still above 0.2 volt, replace positive battery cable. 5. If resistance tests detect no feed circuit failures, remove starter motor and proceed to "Starter Solenoid Bench Test." Starter Control Circuit Test Notes The starter control circuit consists of a starter solenoid, starter relay, ignition switch and clutch pedal interlock switch (manual transmission) or neutral safety switch (automatic transmission). Disable ignition system on gasoline engines or fuel system on diesel engines prior to performing test procedures. Solenoid Test 1. Connect heavy jumper wire on starter relay between battery and solenoid terminals. If engine cranks, perform starter relay test. 2. If engine does not crank or solenoid chatters, check wiring and connectors from relay to starter for loose or corroded connections. 3. Repeat test and, if engine still does not crank properly, repair or replace starter as necessary. Starter Relay Test Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Troubleshooting > Page 6236 Fig 4 Starter Relay Tests 1. Remove starter relay from relay center. 2. Perform testing procedure. Clutch Pedal Switch The clutch pedal switch is a normally open type switch. 1. Locate and disconnect clutch pedal switch connector. 2. Using a suitable continuity tester, check circuit through switch with pedal released, there should be no continuity. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Troubleshooting > Page 6237 3. With continuity tester still attached, push clutch pedal to floor, tester should show full continuity. 4. Tester should not show continuity until pedal is fully depressed, replace switch if it fails any test. Starter Solenoid Bench Test Fig 6 Bosch Starter Solenoid Terminal Identification Fig 7 Nippondenso Starter Solenoid Terminal Identification 1. Remove starter assembly from vehicle. 2. Disconnect field coil wire from field coil terminal. 3. Check for continuity between solenoid terminal and field coil terminal. Continuity should exist. 4. Check for continuity between solenoid terminal and solenoid housing. Continuity should exist. 5. If there is no continuity in either step 3 or 4, solenoid has an open circuit and must be replaced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Page 6238 Starter Motor: Service and Repair 1. Disconnect battery ground cable, then raise and support vehicle. 2. Remove starter motor attaching bolts and nuts. 3. Disconnect all electrical connectors from starter motor and remove starter. 4. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 6242 In Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 6243 Starter Relay: Testing and Inspection Fig 4 Starter Relay Tests 1. Remove starter relay from relay center. 2. Perform testing procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Testing and Inspection > Solenoid Test Starter Solenoid: Testing and Inspection Solenoid Test 1. Connect heavy jumper wire on starter relay between battery and solenoid terminals. If engine cranks, perform starter relay test. 2. If engine does not crank or solenoid chatters, check wiring and connectors from relay to starter for loose or corroded connections. 3. Repeat test and, if engine still does not crank properly, repair or replace starter as necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Testing and Inspection > Solenoid Test > Page 6248 Starter Solenoid: Testing and Inspection Starter Solenoid Bench Test Fig 6 Bosch Starter Solenoid Terminal Identification Fig 7 Nippondenso Starter Solenoid Terminal Identification 1. Remove starter assembly from vehicle. 2. Disconnect field coil wire from field coil terminal. 3. Check for continuity between solenoid terminal and field coil terminal. Continuity should exist. 4. Check for continuity between solenoid terminal and solenoid housing. Continuity should exist. 5. If there is no continuity in either step 3 or 4, solenoid has an open circuit and must be replaced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations Power Distribution Center: Locations Relay Locations Relays mounted under hood on driver's side fender well. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions Power Distribution Center: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6255 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6256 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6257 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6258 Power Distribution Center: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6259 Power Distribution Center: Electrical Diagrams Fig. 16 Fuse Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6260 Fuseblock Module (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6261 Fuseblock Module (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6262 Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6263 Power Distribution Center (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6264 Fig. 17 Relay Bank Identification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6265 Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6266 Micro Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center Fuse: Locations Power Distribution Center Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6271 Power Distribution Center (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6272 Fig. 16 Fuse Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6273 Fuse: Locations Fuse Block Module Fuseblock Module (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6274 Fuseblock Module (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6277 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6278 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6279 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6280 Fuse: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6281 Fuse: Electrical Diagrams Fuse Application Chart (Part 1 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6282 Fuse Application Chart (Part 2 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6283 Fuse Application Chart (Part 3 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6284 Fuse Application Chart (Part 4 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 6285 Fuse: Service Precautions When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Technical Service Bulletins > Customer Interest for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle in Lower Left Dash Area Fuse Block: Customer Interest Fuse Block - Rattle in Lower Left Dash Area NO.: 08-46-93 Rev. A GROUP: Electrical DATE: Dec. 17, 1993 SUBJECT: Fuse Block Mounting Tabs Cracked THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-46-93 DATED OCT. 8, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS SPECIAL SERVICE ONLY REPAIR PARTS AND THE PROCEDURE TO INSTALL THEM. MODELS: 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 09/20/93 (MDH 092006). SYMPTOM/CONDITION: A rattle may be heard at the lower left area of the instrument panel. This condition can be caused by the mounting tabs of the fuse block cracking and coming loose from the mounting bracket. DIAGNOSIS: Inspect the fuse block for looseness and/or cracks at the mounting tabs. If cracks are discovered, perform the repair procedure. If no cracks are found, tighten the screws attaching the fuse block to 20 In.Lbs. (2.3 N-m). PARTS REQUIRED: 1 4773171 Bracket 1 4773172 Bracket REPAIR PROCEDURE: This bulletin involves installing revised fuse block mounting brackets. 1. Using the procedure outlined starting on Page 8E-17 of the 1994 Town & Country/Caravan/Voyager Service Manual (Publication No. 81-3704105), remove the steering column cover. 2. Remove the two screws attaching the fuse block bracket to the instrument panel bracing. 3. Remove the two screws attaching the bracket to the fuse block. Discard the bracket. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Technical Service Bulletins > Customer Interest for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle in Lower Left Dash Area > Page 6294 4. Using the two screws that attached the original bracket to the fuse block, assemble the service brackets (P/N 4773171 and P/N 4773172) to the fuse block as shown in the illustration. Tighten the screws to 20 In.Lbs. (2.3 N-m). 6. Reverse steps 1 through 3 to reinstall the fuse block. Use the original screws and tighten them to 20 In.Lbs. (2.3 N-m). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-90-92 0.3 Hrs. FAILURE CODE: 11 - Broken or Cracked Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle in Lower Left Dash Area Fuse Block: All Technical Service Bulletins Fuse Block - Rattle in Lower Left Dash Area NO.: 08-46-93 Rev. A GROUP: Electrical DATE: Dec. 17, 1993 SUBJECT: Fuse Block Mounting Tabs Cracked THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-46-93 DATED OCT. 8, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS SPECIAL SERVICE ONLY REPAIR PARTS AND THE PROCEDURE TO INSTALL THEM. MODELS: 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 09/20/93 (MDH 092006). SYMPTOM/CONDITION: A rattle may be heard at the lower left area of the instrument panel. This condition can be caused by the mounting tabs of the fuse block cracking and coming loose from the mounting bracket. DIAGNOSIS: Inspect the fuse block for looseness and/or cracks at the mounting tabs. If cracks are discovered, perform the repair procedure. If no cracks are found, tighten the screws attaching the fuse block to 20 In.Lbs. (2.3 N-m). PARTS REQUIRED: 1 4773171 Bracket 1 4773172 Bracket REPAIR PROCEDURE: This bulletin involves installing revised fuse block mounting brackets. 1. Using the procedure outlined starting on Page 8E-17 of the 1994 Town & Country/Caravan/Voyager Service Manual (Publication No. 81-3704105), remove the steering column cover. 2. Remove the two screws attaching the fuse block bracket to the instrument panel bracing. 3. Remove the two screws attaching the bracket to the fuse block. Discard the bracket. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle in Lower Left Dash Area > Page 6300 4. Using the two screws that attached the original bracket to the fuse block, assemble the service brackets (P/N 4773171 and P/N 4773172) to the fuse block as shown in the illustration. Tighten the screws to 20 In.Lbs. (2.3 N-m). 6. Reverse steps 1 through 3 to reinstall the fuse block. Use the original screws and tighten them to 20 In.Lbs. (2.3 N-m). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-90-92 0.3 Hrs. FAILURE CODE: 11 - Broken or Cracked Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Technical Service Bulletins > Page 6301 Fuse Block: Locations Fuse panel is located below left side of instrument panel. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6304 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6305 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6306 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6307 Fuse Block: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6308 Fuse Block: Electrical Diagrams Fuse Application Chart (Part 1 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6309 Fuse Application Chart (Part 2 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6310 Fuse Application Chart (Part 3 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6311 Fuse Application Chart (Part 4 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6312 Power Distribution Center (Part 1 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6313 Power Distribution Center (Part 2 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6314 Power Distribution Center (Part 3 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6315 Power Distribution Center (Part 4 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6316 Fuse Block: Mechanical Diagrams Fig. 16 Fuse Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6317 Fuseblock Module (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6318 Fuseblock Module (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6319 Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6320 Power Distribution Center (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Service and Repair Fusible Link: Service and Repair Purpose Fusible links protect vehicle electrical systems from damage due to excessive current. ^ The most common cause of excessive current is a short to ground caused by a component or wiring failure. Fusible links are color coded to indicate wire gauge and size. Fig. 9 Fusible Link Chart CAUTION: Replace blown fusible links with correct gauge, hypalon insulated, fusible type wire ONLY. ^ Use of standard wire may result in severe damage to the electrical system or an electrical fire. NOTE: Refer to the fusible link chart and the wiring diagrams for proper color and gauge identification. Replacement Splicing Wires CAUTION: If a fusible link has blown, find the cause before attempting to replace the link. NOTE: If a faulty fusible link is suspected, it is important to carefully check the link for continuity over its entire length. In some instances the link may look fine and actually be blown. 1. Disconnect battery negative cable. 2. Cut out the blown portion of the fusible link. 3. Strip 1 inch of insulation from each end of the existing fusible link. 4. Place a piece of heat shrink tubing long enough to cover and seal the entire repair area over one side of the fusible link. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Service and Repair > Page 6324 5. Cut a replacement piece of fusible link approximately two inches longer than the piece removed. 6. Remove one inch of insulation from each end of the replacement fusible link. 7. Spread the stripped ends of the wires apart (example 1). 8. Push the stripped ends of the wires together until the cut ends almost touch the insulation of the other wire (example 2). 9. Twist the wires together (example 3). 10. Solder the wires together using rosin core type solder only. Never use acid core type solder for soldering electrical/electronic connections. 11. Center the heat shrink tubing over the joint. Heat the joint with a heat gun until the tubing is tightly sealed and sealant is coming out of both ends of the tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 6330 Micro Relay Block: Locations Power Distribution Center Identification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 6331 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 6332 Fig. 17 Relay Bank Identification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 6333 Micro Relay Block: Locations Micro Relay Block and Relay Bank Location Relay Bank is located near the fuse box and Micro Relay Bank is located behind center of instrument panel. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions Micro Relay Block: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6336 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6337 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6338 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6339 Micro Relay Block: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6340 Micro Relay Block: Connector Views Micro Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6341 Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6342 Micro Relay Block: Electrical Diagrams Power Distribution Center (Part 1 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6343 Power Distribution Center (Part 2 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6344 Power Distribution Center (Part 3 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6345 Power Distribution Center (Part 4 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 6350 Micro Relay Block: Locations Power Distribution Center Identification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 6351 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 6352 Fig. 17 Relay Bank Identification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 6353 Micro Relay Block: Locations Micro Relay Block and Relay Bank Location Relay Bank is located near the fuse box and Micro Relay Bank is located behind center of instrument panel. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions Micro Relay Block: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6356 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6357 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6358 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6359 Micro Relay Block: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6360 Micro Relay Block: Connector Views Micro Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6361 Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6362 Micro Relay Block: Electrical Diagrams Power Distribution Center (Part 1 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6363 Power Distribution Center (Part 2 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6364 Power Distribution Center (Part 3 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6365 Power Distribution Center (Part 4 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations Power Distribution Center: Locations Relay Locations Relays mounted under hood on driver's side fender well. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions Power Distribution Center: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6372 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6373 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6374 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6375 Power Distribution Center: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6376 Power Distribution Center: Electrical Diagrams Fig. 16 Fuse Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6377 Fuseblock Module (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6378 Fuseblock Module (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6379 Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6380 Power Distribution Center (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6381 Fig. 17 Relay Bank Identification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6382 Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6383 Micro Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center Fuse: Locations Power Distribution Center Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6388 Power Distribution Center (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6389 Fig. 16 Fuse Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6390 Fuse: Locations Fuse Block Module Fuseblock Module (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6391 Fuseblock Module (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6394 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6395 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6396 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6397 Fuse: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6398 Fuse: Electrical Diagrams Fuse Application Chart (Part 1 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6399 Fuse Application Chart (Part 2 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6400 Fuse Application Chart (Part 3 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6401 Fuse Application Chart (Part 4 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 6402 Fuse: Service Precautions When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Technical Service Bulletins > Customer Interest for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle in Lower Left Dash Area Fuse Block: Customer Interest Fuse Block - Rattle in Lower Left Dash Area NO.: 08-46-93 Rev. A GROUP: Electrical DATE: Dec. 17, 1993 SUBJECT: Fuse Block Mounting Tabs Cracked THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-46-93 DATED OCT. 8, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS SPECIAL SERVICE ONLY REPAIR PARTS AND THE PROCEDURE TO INSTALL THEM. MODELS: 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 09/20/93 (MDH 092006). SYMPTOM/CONDITION: A rattle may be heard at the lower left area of the instrument panel. This condition can be caused by the mounting tabs of the fuse block cracking and coming loose from the mounting bracket. DIAGNOSIS: Inspect the fuse block for looseness and/or cracks at the mounting tabs. If cracks are discovered, perform the repair procedure. If no cracks are found, tighten the screws attaching the fuse block to 20 In.Lbs. (2.3 N-m). PARTS REQUIRED: 1 4773171 Bracket 1 4773172 Bracket REPAIR PROCEDURE: This bulletin involves installing revised fuse block mounting brackets. 1. Using the procedure outlined starting on Page 8E-17 of the 1994 Town & Country/Caravan/Voyager Service Manual (Publication No. 81-3704105), remove the steering column cover. 2. Remove the two screws attaching the fuse block bracket to the instrument panel bracing. 3. Remove the two screws attaching the bracket to the fuse block. Discard the bracket. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Technical Service Bulletins > Customer Interest for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle in Lower Left Dash Area > Page 6411 4. Using the two screws that attached the original bracket to the fuse block, assemble the service brackets (P/N 4773171 and P/N 4773172) to the fuse block as shown in the illustration. Tighten the screws to 20 In.Lbs. (2.3 N-m). 6. Reverse steps 1 through 3 to reinstall the fuse block. Use the original screws and tighten them to 20 In.Lbs. (2.3 N-m). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-90-92 0.3 Hrs. FAILURE CODE: 11 - Broken or Cracked Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle in Lower Left Dash Area Fuse Block: All Technical Service Bulletins Fuse Block - Rattle in Lower Left Dash Area NO.: 08-46-93 Rev. A GROUP: Electrical DATE: Dec. 17, 1993 SUBJECT: Fuse Block Mounting Tabs Cracked THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-46-93 DATED OCT. 8, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS SPECIAL SERVICE ONLY REPAIR PARTS AND THE PROCEDURE TO INSTALL THEM. MODELS: 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO 09/20/93 (MDH 092006). SYMPTOM/CONDITION: A rattle may be heard at the lower left area of the instrument panel. This condition can be caused by the mounting tabs of the fuse block cracking and coming loose from the mounting bracket. DIAGNOSIS: Inspect the fuse block for looseness and/or cracks at the mounting tabs. If cracks are discovered, perform the repair procedure. If no cracks are found, tighten the screws attaching the fuse block to 20 In.Lbs. (2.3 N-m). PARTS REQUIRED: 1 4773171 Bracket 1 4773172 Bracket REPAIR PROCEDURE: This bulletin involves installing revised fuse block mounting brackets. 1. Using the procedure outlined starting on Page 8E-17 of the 1994 Town & Country/Caravan/Voyager Service Manual (Publication No. 81-3704105), remove the steering column cover. 2. Remove the two screws attaching the fuse block bracket to the instrument panel bracing. 3. Remove the two screws attaching the bracket to the fuse block. Discard the bracket. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse Block: > 084693A > Dec > 93 > Fuse Block - Rattle in Lower Left Dash Area > Page 6417 4. Using the two screws that attached the original bracket to the fuse block, assemble the service brackets (P/N 4773171 and P/N 4773172) to the fuse block as shown in the illustration. Tighten the screws to 20 In.Lbs. (2.3 N-m). 6. Reverse steps 1 through 3 to reinstall the fuse block. Use the original screws and tighten them to 20 In.Lbs. (2.3 N-m). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-90-92 0.3 Hrs. FAILURE CODE: 11 - Broken or Cracked Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Technical Service Bulletins > Page 6418 Fuse Block: Locations Fuse panel is located below left side of instrument panel. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6421 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6422 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6423 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6424 Fuse Block: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6425 Fuse Block: Electrical Diagrams Fuse Application Chart (Part 1 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6426 Fuse Application Chart (Part 2 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6427 Fuse Application Chart (Part 3 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6428 Fuse Application Chart (Part 4 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6429 Power Distribution Center (Part 1 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6430 Power Distribution Center (Part 2 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6431 Power Distribution Center (Part 3 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6432 Power Distribution Center (Part 4 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6433 Fuse Block: Mechanical Diagrams Fig. 16 Fuse Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6434 Fuseblock Module (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6435 Fuseblock Module (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6436 Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6437 Power Distribution Center (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Service and Repair Fusible Link: Service and Repair Purpose Fusible links protect vehicle electrical systems from damage due to excessive current. ^ The most common cause of excessive current is a short to ground caused by a component or wiring failure. Fusible links are color coded to indicate wire gauge and size. Fig. 9 Fusible Link Chart CAUTION: Replace blown fusible links with correct gauge, hypalon insulated, fusible type wire ONLY. ^ Use of standard wire may result in severe damage to the electrical system or an electrical fire. NOTE: Refer to the fusible link chart and the wiring diagrams for proper color and gauge identification. Replacement Splicing Wires CAUTION: If a fusible link has blown, find the cause before attempting to replace the link. NOTE: If a faulty fusible link is suspected, it is important to carefully check the link for continuity over its entire length. In some instances the link may look fine and actually be blown. 1. Disconnect battery negative cable. 2. Cut out the blown portion of the fusible link. 3. Strip 1 inch of insulation from each end of the existing fusible link. 4. Place a piece of heat shrink tubing long enough to cover and seal the entire repair area over one side of the fusible link. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Service and Repair > Page 6441 5. Cut a replacement piece of fusible link approximately two inches longer than the piece removed. 6. Remove one inch of insulation from each end of the replacement fusible link. 7. Spread the stripped ends of the wires apart (example 1). 8. Push the stripped ends of the wires together until the cut ends almost touch the insulation of the other wire (example 2). 9. Twist the wires together (example 3). 10. Solder the wires together using rosin core type solder only. Never use acid core type solder for soldering electrical/electronic connections. 11. Center the heat shrink tubing over the joint. Heat the joint with a heat gun until the tubing is tightly sealed and sealant is coming out of both ends of the tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 6447 Micro Relay Block: Locations Power Distribution Center Identification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 6448 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 6449 Fig. 17 Relay Bank Identification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 6450 Micro Relay Block: Locations Micro Relay Block and Relay Bank Location Relay Bank is located near the fuse box and Micro Relay Bank is located behind center of instrument panel. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions Micro Relay Block: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6453 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6454 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6455 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6456 Micro Relay Block: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6457 Micro Relay Block: Connector Views Micro Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6458 Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6459 Micro Relay Block: Electrical Diagrams Power Distribution Center (Part 1 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6460 Power Distribution Center (Part 2 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6461 Power Distribution Center (Part 3 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6462 Power Distribution Center (Part 4 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 6467 Micro Relay Block: Locations Power Distribution Center Identification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 6468 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 6469 Fig. 17 Relay Bank Identification Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Locations > Power Distribution Center Location > Page 6470 Micro Relay Block: Locations Micro Relay Block and Relay Bank Location Relay Bank is located near the fuse box and Micro Relay Bank is located behind center of instrument panel. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions Micro Relay Block: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6473 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6474 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6475 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6476 Micro Relay Block: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6477 Micro Relay Block: Connector Views Micro Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6478 Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6479 Micro Relay Block: Electrical Diagrams Power Distribution Center (Part 1 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6480 Power Distribution Center (Part 2 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6481 Power Distribution Center (Part 3 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Power and Ground Distribution > Micro Relay Block <--> [Relay Box] > Component Information > Diagrams > Diagram Information and Instructions > Page 6482 Power Distribution Center (Part 4 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front Alignment Specifications Alignment: Specifications Front Alignment Specifications Caster, Degrees .................................................................................................................................. .................................................................... +1.3 [01] Camber, Degrees ............................................ .............................................................................................................................................................. .... 0.3 Toe-In, Inch .............................................................................................................................. ..................................................................................... 1/16 Ball Joint Wear ...................................... .............................................................................................................................................................. ........... [03] [01] -- Reference angle only, not adjustable. [03] -- Refer to Ball Joint Inspection in Front Steering & Suspension section. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front Alignment Specifications > Page 6488 Alignment: Specifications Rear Alignment Specifications Caster, Degrees .................................................................................................................................. .................................................................................. -- Camber, Degrees .......................................... .............................................................................................................................................................. ...... -0.2 Toe-In, Inch ........................................................................................................................... ....................................................................................... 0 [01] Ball Joint Wear .................................. .............................................................................................................................................................. ................ [04] [01] -- Toe-out when vehicle is backed onto alignment rack is toe-in when driving. [04] -- Refer to Ball Joint Inspection in Rear Steering & Suspension section. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Alignment Alignment: Service and Repair Front Alignment Adjustment CASTER The caster angle on these vehicles cannot be adjusted. Fig. 1 Camber Adjustment CAMBER To adjust camber, loosen cam and through bolts. Rotate upper cam bolt to move top of wheel in or out to achieve specified camber angle. Torque cam bolt nut to 75 ft. lbs. plus an additional 1/4 turn. Fig. 2 Toe-in Adjustment TOE-IN Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Alignment > Page 6491 To adjust toe-in, center steering wheel and hold in position with a suitable tool. Loosen tie rod locknuts and rotate rod to adjust toe-in to specifications. Use care not to twist steering gear rubber boots. Torque tie rod locknuts to 55 ft. lbs. Adjust position of steering gear rubber boots. Remove steering wheel holding tool. Preliminary Inspection 1. Tires are at recommended pressure, are of equal size and have approximately the same wear pattern 2. Check front wheel and tire assembly for radial runout and inspect lower ball joints and steering linkage for looseness. 3. Check front and rear springs for sagging or damage. 4. Front suspension inspections should be performed on a level floor or alignment rack with fuel tank at capacity, and vehicle free of luggage and passenger compartment load. 5. Prior to each alignment reading, vehicle should be bounced an equal number of times from center of the bumper alternating first from rear, then front, and releasing at bottom of down cycle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Alignment > Page 6492 Alignment: Service and Repair Rear Alignment FWD MODELS Fig. 3 Shim Installation For Toe-out (FWD) Fig. 4 Shim Installation For Toe-in (FWD) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Alignment > Page 6493 Fig. 5 Shim Installation For Positive Camber (FWD) Fig. 6 Shim Installation For Negative Camber (FWD) Alignment adjustment is made by adding .010 inch shims between spindle mounting surface and axle casting. Each shim equals wheel change by 0.3.° When recording rear toe-in (vehicle backed onto alignment rack) remember to reverse sign convention. Install alignment shims as follows; 1. Raise and support vehicle, then remove wheel. 2. Remove brake drum, then loosen four brake assembly and spindle mounting bolts enough to allow clearance for shim installation. Do not remove mounting bolts. 3. Install shims as shown. No more than 2 shims on each spindle should be used to bring alignment within acceptable range. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Service and Repair Ball Stud: Service and Repair Fig. 18 Steering Knuckle Assembly REMOVAL 1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. NOTE: Hub and driveshaft are splined together through knuckle (bearing) and retained by hub nut. 3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut. Ensure splined driveshaft is free to separate from spline in hub during knuckle removal. A pulling force on shaft can separate inner CV joint. Tap lightly with brass drift, if required. 5. Disconnect tie rod end from steering arm with a suitable puller. 6. Disconnect brake hose retainer from strut damper. 7. Remove clamp bolt securing ball joint stud into steering knuckle, then brake caliper adapter screw and washer assemblies. 8. Support caliper with a piece of wire. Do not hang by brake hose. 9. Remove rotor, then separate ball joint stud from knuckle assembly. 10. Remove knuckle assembly from vehicle. Support driveshaft during knuckle removal. Do not permit driveshaft to hang after separating steering knuckle from vehicle. INSTALLATION 1. Place steering knuckle on lower ball joint stud and driveshaft through hub. 2. Install and tighten ball joint to steering knuckle clamp bolt to specifications. 3. Install tie rod end into steering arm and tighten nut to specifications. Install cotter pin. 4. Install rotor. 5. Install caliper over rotor and position adapter to steering knuckle. Install adapter to knuckle attaching bolts and tighten to specifications. 6. Attach brake hose retainer to strut damper and tighten attaching screw to specifications. 7. Install hub nut assembly as follows: a. With brakes applied, install hub nut and tighten to specifications. b. Install spring washer, locknut and new cotter pin. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications Power Steering Pump: Specifications Power Steering Specifications Part 1 Of 2 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 6502 Power Steering Specifications Part 2 Of 2 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Description and Operation > Vane Type Power Steering Pump W/Integral Reservoir Power Steering Pump: Description and Operation Vane Type Power Steering Pump W/Integral Reservoir DESCRIPTION The hydraulic pump is a submerged, vane-type design. Submerged pumps have a housing and internal parts inside the reservoir and operate submerged in fluid. OPERATION There are two openings at the rear of the pump housing. The larger opening contains the cam ring, pressure plate, thrust plate, rotor and vane assembly and the end plate. The smaller opening contains the pressure line union, flow control valve, and spring. The flow control orifice is part of the pressure line union. The pressure relief valve, located inside the flow control valve, limits pump pressure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Description and Operation > Vane Type Power Steering Pump W/Integral Reservoir > Page 6505 Power Steering Pump: Description and Operation Vane Type Power Steering Pump Less Integral Reservoir DESCRIPTION The hydraulic pump is a non-submerged vane-type design. The housing and internal parts are separate from the reservoir and are not submerged in fluid. OPERATION There are two bore openings at the rear of the pump housing. The larger opening contains the cam ring, pressure plate, thrust plate, rotor and vane assembly, and end plate. The smaller opening contains the pressure line union, flow control valve and spring. The pressure relief valve inside the flow control valve limits pump pressure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Excessive Steering Wheel Play Power Steering Pump: Testing and Inspection Excessive Steering Wheel Play 1. Excessive play in steering gearbox. 2. Loose steering gear. 3. Loose or worn tie rod end stud. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Excessive Steering Wheel Play > Page 6508 Power Steering Pump: Testing and Inspection Hard Steering Wheel Operation 1. Air in fluid line. 2. Loose or damaged belt. 3. Low or leaking fluid. 4. Twisted or damaged power steering hoses. 5. Gearbox or pump malfunction. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Excessive Steering Wheel Play > Page 6509 Power Steering Pump: Testing and Inspection Noisy Operation 1. Loose oil pump or gearbox. 2. Loose pulley nut. 3. Interference between pressure hose and other parts. 4. Air entering oil pump. 5. Pump seizure. 6. Loose belt. 7. Gearbox port section damage. 8. Return hose malfunction. 9. Loose oil pump or pump bracket. 10. Excessive oil pump body wear. 11. Malfunctioning steering stopper. 12. Wheel and tire to body interference. 13. Malfunctioning gearbox. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Excessive Steering Wheel Play > Page 6510 Power Steering Pump: Testing and Inspection Oil Leaks Pump Oil Leak Checking. Saginaw Submerged Vane Pump W/intregal Reservoir (P Type) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Excessive Steering Wheel Play > Page 6511 Pump Oil Leak Checking. Saginaw Vane Pump W/external Reservoir (TC Type) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul Power Steering Pump: Service and Repair Power Steering Pump Overhaul Vane Type Power Steering Pump w/ Integral Reservoir Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 6514 DISASSEMBLE NOTE: Before disassembly of pump, remove filler cap and drain fluid. If broken components or foreign materials are found during disassembly, hydraulic system should be disassembled, inspected, cleaned and flushed before servicing is complete. 1. Clean exterior of pump with solvent and crocus cloth. 2. Remove bolt and fitting from rear of pump reservoir, then the reservoir and seals. 3. Remove end plate retaining ring using a screwdriver and punch. 4. Remove endplate and pressure plate spring, then the O-ring, control valve and control valve spring by inverting housing. 5. Tap lightly on driveshaft with a rubber mallet to remove pressure plate. 6. Pull out pump ring and vanes, then remove shaft retaining ring, pump rotor and thrust plate. 7. Remove driveshaft key from slot in shaft, then with end of shaft pointed downward, press down until shaft is free. 8. Remove seals, dowel pins and O-rings. INSPECTION 1. Clean all parts with solvent and blow dry. 2. Check vane tips for scoring or wear. Vanes must fit snugly but slide freely in slots of rotor. Examine rotor slots for burrs and excessive wear at thrust faces. 3. Check inner surface of pump ring for scoring or wear and thrust plate and pressure plate for wear on plate surfaces. 4. If heavy wear is evident in any of above components, replace entire rotating group. 5. Inspect seal for leakage, cracking or swelling, if evident replace seal. 6. Check driveshaft for excessive burning or scoring. 7. Control valve must move smoothly in the valve bore. ASSEMBLE 1. Lubricate O-rings, pump ring, rotor and vanes with power steering fluid. 2. Install O-rings and dowel pins on pump housing. 3. Using a seal installation tool, insert seal into front of housing. 4. Install driveshaft and thrust plate. Ensure counterbore faces driveshaft end of housing and install rotor. 5. Insert vanes into rotor, ensuring rounded edge faces away from rotor. 6. Install shaft retaining ring, pump ring and pressure plate. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 6515 7. Insert control valve spring, then install control valve and O-ring. 8. Install pressure plate spring and end plate, then secure with end plate retaining ring. 9. Connect seal and reservoir, then install bolt and fitting TC Series DISASSEMBLE Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 6516 Prior to disassembly of the pump, remove filler cap and drain fluid. If broken components or foreign materials are found during disassembly, then the hydraulic system should be disassembled, inspected, cleaned and flushed before service is complete. 1. Clean exterior of pump with solvent, then clamp front hub of pump into a soft jaw vise. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 6517 2. Pry tab and slide retaining clip off of pump. 3. Remove reservoir, then return tube as follows: a. Install five 5/8 inch washers and a 9/16-12 nut outside of tube. b. Plug tube to prevent chips from entering, then insert a 9/16-12 tap into return tube and turn until tube is pulled out of housing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 6518 4. Remove O-ring, fitting, O-ring seal, flow control valve and spring. 5. Using snap ring pliers, remove retaining ring. Note position of large lug in housing before removal. 6. Remove driveshaft and bearing. Note and measure any clearance between collar and shaft. Press bearing from shaft using a support ring under bearing. 7. Remove driveshaft seal by prying seal loose with a screwdriver. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 6519 8. Insert a punch into access hole, then pry retaining ring loose with a screwdriver. 9. Using a 5/16 inch piece of bar stock or a suitable brass drift, remove thrust plate. 10. Remove pump ring, rotor, vanes and dowel pins. 11. Remove pressure plate and O-ring, then the spring, seal and remaining dowel pin. 12. Using a suitable punch, remove sleeve assembly. INSPECTION 1. Clean all parts with solvent and blow dry. 2. Inspect rotating components as follows: a. Vane tips for scoring or wear. b. Fit of vanes in rotor. Vanes must fit properly in slots without sticking or excessive play. c. Rotor slots for burrs and excessive wear at thrust faces. d. Inner surface of pump ring for scoring or wear. e. Thrust plate and pressure plate for wear on plate surfaces. f. If heavy wear is present, or parts are faulty, replace entire rotating group. 3. Inspect bearing for rough or looseness and bearing seal for leakage, cracking or swelling. 4. Check driveshaft and bearing bore for excessive burning or scoring. 5. Control valve must move smoothly in the valve bore. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 6520 ASSEMBLE 1. Press sleeve into housing using a suitable socket and press. 2. Install dowel pin, seal and pressure plate spring. 3. Install O-ring seal, pressure plate and dowel pins. Mark top of pressure plate where pin enters from underneath to ease alignment with dowel pin during assembly. 4. Lubricate O-ring, pump ring, rotor and vanes with power steering fluid. Install vanes and rotor with rounded edge facing away from rotor. Ensure counterbore of rotor faces driveshaft end of housing. 5. Install pump ring with identification marks facing up, then install O-ring seal and thrust plate. Thrust plate dimples must line up with bolt holes in housing and plate must engage pump ring dowel pins. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 6521 6. Using a press to compress thrust plate, install retaining plate with the center opening of ring with bolt hole nearest the access hole. 7. Using a suitable socket and press, install driveshaft seal into housing until it bottoms. 8. Install bearing onto driveshaft, then slide assembly into housing while rotating driveshaft so shaft serrations engage with rotor. 9. Insert retaining ring ensuring large tab of ring is properly located. Refer to. 10. Install flow control spring, control valve, O-ring seal and O-ring. 11. Install reservoir or return tube, then clips if equipped. CB Series DISASSEMBLE Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 6522 Exploded View Of CB Series Power Steering Pump 1. Remove reservoir retaining clips from reservoir assembly and housing. 2. Separate reservoir from housing, then remove O-ring from reservoir. 3. Remove O-ring union fitting and O-ring. 4. Remove control valve assembly and flow control spring. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 6523 5. Protect drive shaft with shim stock. 6. Using a small chisel, cut drive shaft seal. 7. Remove drive shaft seal from housing. 8. Insert a small punch through access hole in housing, then remove retaining ring from housing. 9. Remove pump internal components by gently pushing on drive shaft. 10. Remove O-ring from pump housing. 11. Remove dowel pins, end cover, pressure plate spring and O-ring from pressure plate. 12. Remove pump ring and vanes from drive shaft subassembly. 13. Remove shaft retaining ring from drive shaft. 14. Remove pump rotor and thrust plate from drive shaft. INSPECTION 1. Check the following parts for any scoring, pitting or chatter marks: a. Pressure plate. b. Pump ring. c. Rotor. d. Vanes. e. Thrust plate. f. Drive shaft. 2. Replace any parts with any signs of excessive wear or damage. ASSEMBLE 1. Clean all parts in power steering fluid, then thoroughly dry all parts. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 6524 2. Lubricate new drive shaft seal with power steering fluid, then install seal into pump housing using suitable seal installation tool or socket. 3. Install pump ring dowel pins into pump housing. 4. Install thrust plate, pump rotor and new shaft retaining ring onto drive shaft. 5. Install drive shaft subassembly into pump housing. 6. Install vanes into pump rotor. 7. Install pump ring onto dowel pins. 8. Lubricate new oil ring with power steering fluid, then install O-ring into end cover. 9. Lubricate outer edge of end cover with power steering fluid, then press end cover into pump housing. 10. Insert O-ring into groove in pump housing with ring opening near access hole in pump housing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 6525 Power Steering Pump: Service and Repair Power Steering Pump Removal and Installation 1. Disconnect battery ground cable, then remove serpentine drive belt. 2. Raise and support vehicle, then place drain pan under vehicle. 3. Disconnect low pressure hose and high pressure line from pump, then remove hose from pump to remote reservoir. 4. Remove right wheel, then the bolts holding pump to generator/power steering/belt tensioner mounting bracket. 5. Remove nut and bolt holding engine block to pump support strut. Remove strut from engine and pump. Lay pump assembly down on top of steering gear. 6. Remove serpentine drive belt tensioner from bracket, then generator/pump bracket and support strut. 7. Lower vehicle, then remove power steering reservoir from vehicle. 8. Remove engine wiring harness routing clip from generator bracket. 9. Loosen bolt holding engine bracket assembly to engine support assembly. 10. Remove upper generator to generator bracket mounting bolt, then rotate generator assembly back toward dash panel. 11. Remove generator bracket from engine and intake manifold. 12. Remove lower generator mounting bolt. With wiring harness connected, remove generator and place on intake manifold. 13. Remove power steering pump out through top, in area between engine and dash panel where generator was mounted. 14. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least ten minutes after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 6531 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming ARMING 1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate SRS system is functioning correctly. 5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air Bag Systems/Testing and Inspection. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Mechanical Specifications Steering Gear: Mechanical Specifications Component .......................................................................................................................................... ....................................................... Torque/Ft. Lbs. High Pressure Hose Tube Nuts ........................................................................................................... ............................................................................... 25 Return Tube Nut ............................................. .............................................................................................................................................................. ...... 25 Steering Gear to Subframe Bolts ............................................................................................. ........................................................................................... 50 Tie Rod End Locknut .......................... .............................................................................................................................................................. ................. 55 Tie Rod End To Steering Knuckle Attaching Nut .............................................................................................................................................................. 35 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Mechanical Specifications > Page 6536 Steering Gear: Pressure, Vacuum and Temperature Specifications Initial Pressure, psi .............................................................................................................................. .......................................................................... 50-80 Maximum Pressure, psi .................................. .............................................................................................................................................................. .. 1300 Relief Pressure, psi ................................................................................................................. .............................................................................. 1200-1300 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 6537 Steering Gear: Application and ID Steering Gear ...................................................................................................................................... .................................................. TRW Rack & Pinion Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 6538 Steering Gear: Description and Operation Rack & Pinion Steering Gear The steering gear assembly used on Chrysler Corp. front wheel drive trucks and vans and Dodge Dakota, consists of a housing which contains a toothed rack, a pinion, rack slipper and rack slipper spring. The steering gear rack and pinion assembly converts rotational movement of the pinion assembly into transverse movement of the rack. Tie rods and tie rod ends transmit this movement to the steering arms and wheels while accommodating suspension movement at the same time. The tie rods are coupled to the ends of the rack. This connection is protected by a bellows type oil seal which retains steering gear lubricant. The pinion runs on straddle mounted ball bearings. The lower bearing is incorporated in the pinion housing. The upper bearing is swagged to the pinion shaft. Lock to lock stops are built into the steering gear. The 1991-92 Dakota rack and pinion gears have a larger diameter stud than previous years, so these are not interchangeable. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 6539 Steering Gear: Adjustments 1. With rack placed in center position, attach rack support cover to gear housing, then tighten cover to specifications using torque wrench socket MB990607-A or equivalent. Back off cover approximately 10°, then install and tighten locking nut to specifications. 2. Rotate pinion gear at a rate of one revolution every 4 to 6 seconds using preload socket CT-1108 and a suitable torque wrench. Total pinion preload should be 5-11 lb-in. NOTE: Measure starting torque through whole stroke of rack. 3. If measured values are not within specifications, readjust rack support cover, then recheck. 4. If still not within specifications, check rack support cover, rack support spring and rack support and replace parts as necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > FWD Steering Gear: Service and Repair FWD 1. Raise and support vehicle, then remove front wheels. 2. Remove tie rod ends using a suitable puller. 3. Remove splash shields and boot seal shields, then fluid lines to pump on power steering gear only. 4. Disconnect tie rod ends from steering knuckles. 5. Remove crossmember to steering gear attaching bolts, then steering gear from left side of vehicle. 6. Reverse procedure to install, noting following: a. For manual gear, make sure master serrations are inline. b. Right rear crossmember bolt is a pilot bolt that correctly locates crossmember. Tighten this bolt first. Tighten all four crossmember bolts to specifications. Proper torque is very important. c. Tighten four bolts attaching steering gear to crossmember to specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > FWD > Page 6542 Steering Gear: Service and Repair AWD 1. Remove steering column as described in Steering Column Replacement. 2. Remove tie rod ends from steering knuckle using suitable puller. Fig. 30 Bridge Assembly (AWD) 3. Remove two bolts and two nuts attaching bridge assembly to crossmember. Gain access to bolts through holes in top of bridge assembly. 4. Remove crossmember to frame rail attaching bolts. Using a suitable jack, lower and suspend crossmember from lower control arm. Do not remove crossmember from vehicle. 5. Disconnect power steering pump, pressure and return lines from steering gear. 6. Remove power steering hose to crossmember bracket. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > FWD > Page 6543 Fig. 31 Steering Gear Assembly (AWD) 7. Remove four bolts attaching steering gear to crossover bridge. Note length during removal. 8. Remove lower steering column coupling from steering gear. Drive roll pin from coupler using suitable drift. 9. Remove steering gear from vehicle by pulling out from driver's side wheelwell. 10. Reverse procedure to install. Tighten to specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V305000 > Oct > 00 > Recall 00V305000: Steering Wheel Separation Steering Wheel: Recalls Recall 00V305000: Steering Wheel Separation Vehicle Description: Mini vans equipped with 2-spoke luxury wheels manufactured July 1992 through June 1993; or equipped with 4-spoke sport wheels manufactured from July 1992 through September 1993. The steering wheel armature stamping can crack and separate from the center hub attachment to the steering column. If the steering wheel separates from the center hub attachment to the steering column, loss of control can occur increasing the risk of an accident. Dealers will inspect the steering wheel for cracks and any wheels with cracks will be replaced. All other vehicles will have a reinforcement plate installed to prevent steering wheel separation in the event cracking occurs. Owner notification began November 6, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest: > 081694 > Apr > 94 > Speed Control Switch - Loose/Rattles Steering Wheel: Customer Interest Speed Control Switch - Loose/Rattles NO: 08-16-94 GROUP: Electrical DATE: Apr. 1, 1994 SUBJECT: Speed Control Switch Loose or Rattles MODELS: 1994 (AA) Acclaim/LeBaron Sedan/Spirit (AJ) LeBaron Convertible (AP) Shadow/Sundance (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE STANDARD (NON-LEATHER WRAPPED) STEERING WHEEL, EXCLUDING LONG WHEEL BASE AS-BODY, BUILT PRIOR TO 3/7/94, (MDH 03-07-XX). SYMPTOM/CONDITION: Speed control switch becomes loose or rattles in steering wheel. The most likely cause is cracking of the speed control switch mounting bosses due to lubricant under the paint and on the metal mounting surface of the steering wheel. Additionally, the switch mounting screw holes may be located too far outboard. PARTS REQUIRED: 1 4565265 Speed Control Switch 2 6032986 Screws AR NPN Naphtha Cleaning Solvent (Obtain Locally) REPAIR PROCEDURE: This bulletin involves enlarging the speed control switch mounting holes, cleaning the steering wheel mounting surface, top and bottom, and installing a new speed control switch and mounting screws. 1. Remove the speed control switch from the steering wheel and discard the two mounting screws. NOTE: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE REMOVING THE AIRBAG. FOLLOW ALL WARNINGS IN THE APPROPRIATE SERVICE MANUAL REGARDING AIRBAGS. 2. Remove the steering wheel by removing the airbag module, vibration dampener (if equipped), and speed control wiring as outlined in the appropriate Service Manual. 3. With the steering wheel removed, remove the back cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest: > 081694 > Apr > 94 > Speed Control Switch - Loose/Rattles > Page 6557 4. Secure the steering wheel in a suitable fixture. Drill out both speed control mounting holes using a 1/4" (6 mm) drill (See Illustration). 5. Using 80 to 180 grit sandpaper, clean the paint off both the top and bottom sides of metal mounting surface. Using a round file or knife, clean out both guide pin holes where the speed control switch mounts (See Illustration). 6. Clean loose debris from the sanded area. Using Naphtha cleaning solvent on a clean rag, thoroughly wipe the sanded area on both sides of the steering wheel. Make sure screw and guide pin holes are also cleaned out with solvent. Allow 2-3 minutes for cleaner to evaporate. NOTE: USE ONLY NAPHTHA CLEANING SOLVENT. ANY OTHER SOLVENT WILL NOT BE EFFECTIVE FOR THIS PROCEDURE. WHEN USING NAPHTHA, FOLLOW ALL MANUFACTURERS WARNINGS AND RECOMMENDATIONS AND AVOID CONTACT WITH PLASTIC SURFACES. 7. Reinstall the steering wheel back cover, steering wheel and all other parts removed in Step 2. 8. Install new speed control switch, P/N 4565265, using two new screws, P/N 6032986. NOTE: THE OLD SPEED CONTROL SWITCH MOUNTING SCREWS MUST NOT BE REUSED, AS THEY MAY BE CONTAMINATED WITH LUBRICANT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-85-30-93 0.5 Hrs. FAILURE CODE: BF - Broken Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > NHTSA00V305000 > Oct > 00 > Recall 00V305000: Steering Wheel Separation Steering Wheel: All Technical Service Bulletins Recall 00V305000: Steering Wheel Separation Vehicle Description: Mini vans equipped with 2-spoke luxury wheels manufactured July 1992 through June 1993; or equipped with 4-spoke sport wheels manufactured from July 1992 through September 1993. The steering wheel armature stamping can crack and separate from the center hub attachment to the steering column. If the steering wheel separates from the center hub attachment to the steering column, loss of control can occur increasing the risk of an accident. Dealers will inspect the steering wheel for cracks and any wheels with cracks will be replaced. All other vehicles will have a reinforcement plate installed to prevent steering wheel separation in the event cracking occurs. Owner notification began November 6, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 081694 > Apr > 94 > Speed Control Switch Loose/Rattles Steering Wheel: All Technical Service Bulletins Speed Control Switch - Loose/Rattles NO: 08-16-94 GROUP: Electrical DATE: Apr. 1, 1994 SUBJECT: Speed Control Switch Loose or Rattles MODELS: 1994 (AA) Acclaim/LeBaron Sedan/Spirit (AJ) LeBaron Convertible (AP) Shadow/Sundance (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE STANDARD (NON-LEATHER WRAPPED) STEERING WHEEL, EXCLUDING LONG WHEEL BASE AS-BODY, BUILT PRIOR TO 3/7/94, (MDH 03-07-XX). SYMPTOM/CONDITION: Speed control switch becomes loose or rattles in steering wheel. The most likely cause is cracking of the speed control switch mounting bosses due to lubricant under the paint and on the metal mounting surface of the steering wheel. Additionally, the switch mounting screw holes may be located too far outboard. PARTS REQUIRED: 1 4565265 Speed Control Switch 2 6032986 Screws AR NPN Naphtha Cleaning Solvent (Obtain Locally) REPAIR PROCEDURE: This bulletin involves enlarging the speed control switch mounting holes, cleaning the steering wheel mounting surface, top and bottom, and installing a new speed control switch and mounting screws. 1. Remove the speed control switch from the steering wheel and discard the two mounting screws. NOTE: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE REMOVING THE AIRBAG. FOLLOW ALL WARNINGS IN THE APPROPRIATE SERVICE MANUAL REGARDING AIRBAGS. 2. Remove the steering wheel by removing the airbag module, vibration dampener (if equipped), and speed control wiring as outlined in the appropriate Service Manual. 3. With the steering wheel removed, remove the back cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 081694 > Apr > 94 > Speed Control Switch Loose/Rattles > Page 6567 4. Secure the steering wheel in a suitable fixture. Drill out both speed control mounting holes using a 1/4" (6 mm) drill (See Illustration). 5. Using 80 to 180 grit sandpaper, clean the paint off both the top and bottom sides of metal mounting surface. Using a round file or knife, clean out both guide pin holes where the speed control switch mounts (See Illustration). 6. Clean loose debris from the sanded area. Using Naphtha cleaning solvent on a clean rag, thoroughly wipe the sanded area on both sides of the steering wheel. Make sure screw and guide pin holes are also cleaned out with solvent. Allow 2-3 minutes for cleaner to evaporate. NOTE: USE ONLY NAPHTHA CLEANING SOLVENT. ANY OTHER SOLVENT WILL NOT BE EFFECTIVE FOR THIS PROCEDURE. WHEN USING NAPHTHA, FOLLOW ALL MANUFACTURERS WARNINGS AND RECOMMENDATIONS AND AVOID CONTACT WITH PLASTIC SURFACES. 7. Reinstall the steering wheel back cover, steering wheel and all other parts removed in Step 2. 8. Install new speed control switch, P/N 4565265, using two new screws, P/N 6032986. NOTE: THE OLD SPEED CONTROL SWITCH MOUNTING SCREWS MUST NOT BE REUSED, AS THEY MAY BE CONTAMINATED WITH LUBRICANT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-85-30-93 0.5 Hrs. FAILURE CODE: BF - Broken Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Wheel: > 081694 > Apr > 94 > Speed Control Switch Loose/Rattles Steering Wheel: All Technical Service Bulletins Speed Control Switch - Loose/Rattles NO: 08-16-94 GROUP: Electrical DATE: Apr. 1, 1994 SUBJECT: Speed Control Switch Loose or Rattles MODELS: 1994 (AA) Acclaim/LeBaron Sedan/Spirit (AJ) LeBaron Convertible (AP) Shadow/Sundance (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE STANDARD (NON-LEATHER WRAPPED) STEERING WHEEL, EXCLUDING LONG WHEEL BASE AS-BODY, BUILT PRIOR TO 3/7/94, (MDH 03-07-XX). SYMPTOM/CONDITION: Speed control switch becomes loose or rattles in steering wheel. The most likely cause is cracking of the speed control switch mounting bosses due to lubricant under the paint and on the metal mounting surface of the steering wheel. Additionally, the switch mounting screw holes may be located too far outboard. PARTS REQUIRED: 1 4565265 Speed Control Switch 2 6032986 Screws AR NPN Naphtha Cleaning Solvent (Obtain Locally) REPAIR PROCEDURE: This bulletin involves enlarging the speed control switch mounting holes, cleaning the steering wheel mounting surface, top and bottom, and installing a new speed control switch and mounting screws. 1. Remove the speed control switch from the steering wheel and discard the two mounting screws. NOTE: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE REMOVING THE AIRBAG. FOLLOW ALL WARNINGS IN THE APPROPRIATE SERVICE MANUAL REGARDING AIRBAGS. 2. Remove the steering wheel by removing the airbag module, vibration dampener (if equipped), and speed control wiring as outlined in the appropriate Service Manual. 3. With the steering wheel removed, remove the back cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Wheel: > 081694 > Apr > 94 > Speed Control Switch Loose/Rattles > Page 6573 4. Secure the steering wheel in a suitable fixture. Drill out both speed control mounting holes using a 1/4" (6 mm) drill (See Illustration). 5. Using 80 to 180 grit sandpaper, clean the paint off both the top and bottom sides of metal mounting surface. Using a round file or knife, clean out both guide pin holes where the speed control switch mounts (See Illustration). 6. Clean loose debris from the sanded area. Using Naphtha cleaning solvent on a clean rag, thoroughly wipe the sanded area on both sides of the steering wheel. Make sure screw and guide pin holes are also cleaned out with solvent. Allow 2-3 minutes for cleaner to evaporate. NOTE: USE ONLY NAPHTHA CLEANING SOLVENT. ANY OTHER SOLVENT WILL NOT BE EFFECTIVE FOR THIS PROCEDURE. WHEN USING NAPHTHA, FOLLOW ALL MANUFACTURERS WARNINGS AND RECOMMENDATIONS AND AVOID CONTACT WITH PLASTIC SURFACES. 7. Reinstall the steering wheel back cover, steering wheel and all other parts removed in Step 2. 8. Install new speed control switch, P/N 4565265, using two new screws, P/N 6032986. NOTE: THE OLD SPEED CONTROL SWITCH MOUNTING SCREWS MUST NOT BE REUSED, AS THEY MAY BE CONTAMINATED WITH LUBRICANT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-85-30-93 0.5 Hrs. FAILURE CODE: BF - Broken Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Wheel: > NHTSA00V305000 > Oct > 00 > Recall 00V305000: Steering Wheel Separation Steering Wheel: All Technical Service Bulletins Recall 00V305000: Steering Wheel Separation Vehicle Description: Mini vans equipped with 2-spoke luxury wheels manufactured July 1992 through June 1993; or equipped with 4-spoke sport wheels manufactured from July 1992 through September 1993. The steering wheel armature stamping can crack and separate from the center hub attachment to the steering column. If the steering wheel separates from the center hub attachment to the steering column, loss of control can occur increasing the risk of an accident. Dealers will inspect the steering wheel for cracks and any wheels with cracks will be replaced. All other vehicles will have a reinforcement plate installed to prevent steering wheel separation in the event cracking occurs. Owner notification began November 6, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 6579 Steering Wheel: Service and Repair 1. Ensure front wheels are straight and steering column is locked, then disconnect battery ground cable. 2. Remove four air bag module attaching nuts from back of steering wheel, then lift module and disconnect rear module connector. 3. Remove vehicle speed control switch and connector. 4. Remove steering wheel retaining nut and pull steering wheel with puller tool No. C-3428B, or equivalent. 5. Reverse procedure to install. Torque steering wheel attaching nut to 45 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Specifications Tightening Specifications Part 1 Of 2 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection Ball Joint: Testing and Inspection Fig. 9 Ball Joint Wear Inspection With weight of vehicle resting on wheel and tire assembly, attempt to move grease fitting with fingers. Do not use tool or added force to attempt to move grease fitting. If grease fitting moves freely, ball joint is worn and should be replaced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 6587 Ball Joint: Service and Repair BALL JOINT REMOVAL (1) Pry off seal. (2) Position Receiving Cup Tool C-4699-2 to support lower control arm while receiving ball joint assembly. (3) Install 1-1/16 inch deep socket over ball joint stud and against the ball joint upper housing. (4) Press down against the ball joint upper housing, to remove ball joint assembly from lower control arm. BALL JOINT INSTALLATION (1) By hand, position ball joint assembly into the ball joint bore of the lower control arm. Be sure the ball joint assembly is not cocked in the bore of the control arm, this will cause binding of the ball assembly. (2) Position assembly in press with Installer Tool 1C-4699-1 supporting control arm. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 6588 (3) Install the Receiver Cup, Special Tool C-4699-2 -over the ball joint stud and down on the lower control arm assembly. (4) Carefully align all pieces. Using an arbor press apply pressure against the control arm assembly, until ball joint is fully seated against bottom surface of control arm. Do not apply excessive pressure against the control arm. BALL JOINT SEAL INSTALLATION (1) Support ball joint housing with Installer, Special Tool C-4699-1. Position new seal over ball joint stud and against ball joint housing. (2) With 1-1/2 inch socket, press seal onto ball joint housing until it is squarely seated against top surface of control arm as shown. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair Control Arm: Service and Repair Fig. 12 Lower Control Arm Assembly REMOVAL 1. Raise and support vehicle. 2. Remove front inner pivot through bolt, rear stub strut nut, retainer and bushing, then ball joint to steering knuckle clamp bolt. 3. Separate ball joint from steering knuckle by prying between ball stud retainer and lower control arm. Pulling steering knuckle out from vehicle after releasing from ball joint can separate inner CV joint. 4. Remove sway bar to control arm nut, then rotate control arm over sway bar. 5. Remove rear stub strut bushing, sleeve and retainer. On AWD models, pivot bushings are not serviceable and must be replaced as a unit. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Page 6592 1. Install retainer, bushing and sleeve on stub strut. 2. Position control arm over sway bar, then install rear stub strut and front pivot into crossmember. 3. Install front pivot bolt and loosely assemble nut. 4. Install stub strut bushing and retainer, then loosely assemble nut. 5. Install ball joint stud into steering knuckle, then clamp bolt. Tighten clamp bolt to specifications. 6. Place sway bar end bushing retainer to control arm, then install retainer bolts. Tighten retainer bolts to specifications. 7. Lower vehicle so suspension fully supports vehicle, then tighten front pivot bolt and stub strut nut to specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 220794 > Oct > 94 > Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left Cross-Member: Customer Interest Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left NO: 22-07-94 GROUP: Tires and Wheels DATE: Oct. 21, 1994 SUBJECT: Tire Leads/Drifts Left THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-04-93 DATED JUN. 11, 1993 WHICH SHOULD BE NOTED IN YOUR FILES AND THE 1993 TECHNICAL SERVICE BULLETINS MANUAL (PUBLICATION NO. 81-699-94000). THIS REVISION INCLUDES ADDING 1994 AND 1995 MODEL VEHICLES, ADDS STEP 8 AND CHANGES THE FAILURE CODE. ALL REVISIONS ARE HIGHLIGHTED AND WITH **ASTERISKS**. MODELS: 1991 - **1995** (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Some vehicles may exhibit a tendency to drift left. Road surfaces have significant effect on drift tendencies. DIAGNOSIS: Test drive the vehicle on a road surface that slopes down to the right. On lanes that slope down to the right, the vehicle should track with little or no drift. On lanes that slope down to the left, a slight drift to the left is expected and normal. If the vehicle exhibits a tendency to drift left while in lanes that slope to the right, the following diagnostic procedures should be followed: A. Cross switch the front tire/wheel assemblies and re-evaluate the vehicle. If the drift is corrected, return the vehicle to the customer. If the drift to the left becomes worse, return the tire/wheel assemblies to their original positions and perform step B of the diagnosis. If the drift to the left is unchanged, perform step B of the diagnosis. B. Check and adjust as necessary, the front alignment to the following preferred specifications: Camber: 0.3 degree positive Toe: 0.1 degree in. If the vehicle still drifts left while in lanes that slope to the right, perform the repair procedure. PARTS REQUIRED: 1 6502553 Screw and Washer Assembly REPAIR PROCEDURE: This bulletin involves repositioning the front crossmember. 1. Raise the vehicle on a hoist that leaves the front wheels unsupported. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 220794 > Oct > 94 > Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left > Page 6601 2. Remove the left rear nut and shouldered stud attaching the front crossmember to the frame structure (Refer to the Illustration). 3. Install and finger tighten screw and washer assembly, P/N 6502553, at the left rear attachment position of the front crossmember. 4. Loosen the two front and right rear front crossmember attachments. 5. Using an appropriate pry bar at the left side of the front crossmember, rotate the front crossmember assembly forward using the right rear attachment as the pivot point for the rotation (looking at the front crossmember from underneath the vehicle, this will be a counterclockwise rotation). Rotate the crossmember until it contacts the left rear crossmember fastener. 6. Torque the four front crossmember fasteners to 110 ft.lbs. while the crossmember's position is held against the left rear fastener. 7. Check and adjust as necessary, the front alignment to the following preferred specifications: Camber: 0.3 degree positive Toe: 0.1 degree in. **8. If the vehicle still exhibits a left lead condition, contact your zone office for further assistance.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 02-00-01-95 (Includes Alignment) 1.0 Hrs. FAILURE CODE: **LL - Leads Left** Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 220794 > Oct > 94 > Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left Cross-Member: All Technical Service Bulletins Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left NO: 22-07-94 GROUP: Tires and Wheels DATE: Oct. 21, 1994 SUBJECT: Tire Leads/Drifts Left THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-04-93 DATED JUN. 11, 1993 WHICH SHOULD BE NOTED IN YOUR FILES AND THE 1993 TECHNICAL SERVICE BULLETINS MANUAL (PUBLICATION NO. 81-699-94000). THIS REVISION INCLUDES ADDING 1994 AND 1995 MODEL VEHICLES, ADDS STEP 8 AND CHANGES THE FAILURE CODE. ALL REVISIONS ARE HIGHLIGHTED AND WITH **ASTERISKS**. MODELS: 1991 - **1995** (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Some vehicles may exhibit a tendency to drift left. Road surfaces have significant effect on drift tendencies. DIAGNOSIS: Test drive the vehicle on a road surface that slopes down to the right. On lanes that slope down to the right, the vehicle should track with little or no drift. On lanes that slope down to the left, a slight drift to the left is expected and normal. If the vehicle exhibits a tendency to drift left while in lanes that slope to the right, the following diagnostic procedures should be followed: A. Cross switch the front tire/wheel assemblies and re-evaluate the vehicle. If the drift is corrected, return the vehicle to the customer. If the drift to the left becomes worse, return the tire/wheel assemblies to their original positions and perform step B of the diagnosis. If the drift to the left is unchanged, perform step B of the diagnosis. B. Check and adjust as necessary, the front alignment to the following preferred specifications: Camber: 0.3 degree positive Toe: 0.1 degree in. If the vehicle still drifts left while in lanes that slope to the right, perform the repair procedure. PARTS REQUIRED: 1 6502553 Screw and Washer Assembly REPAIR PROCEDURE: This bulletin involves repositioning the front crossmember. 1. Raise the vehicle on a hoist that leaves the front wheels unsupported. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 220794 > Oct > 94 > Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left > Page 6607 2. Remove the left rear nut and shouldered stud attaching the front crossmember to the frame structure (Refer to the Illustration). 3. Install and finger tighten screw and washer assembly, P/N 6502553, at the left rear attachment position of the front crossmember. 4. Loosen the two front and right rear front crossmember attachments. 5. Using an appropriate pry bar at the left side of the front crossmember, rotate the front crossmember assembly forward using the right rear attachment as the pivot point for the rotation (looking at the front crossmember from underneath the vehicle, this will be a counterclockwise rotation). Rotate the crossmember until it contacts the left rear crossmember fastener. 6. Torque the four front crossmember fasteners to 110 ft.lbs. while the crossmember's position is held against the left rear fastener. 7. Check and adjust as necessary, the front alignment to the following preferred specifications: Camber: 0.3 degree positive Toe: 0.1 degree in. **8. If the vehicle still exhibits a left lead condition, contact your zone office for further assistance.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 02-00-01-95 (Includes Alignment) 1.0 Hrs. FAILURE CODE: **LL - Leads Left** Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Service and Repair Ball Stud: Service and Repair Fig. 18 Steering Knuckle Assembly REMOVAL 1. Remove cotter pin, locknut and spring washer. 2. Loosen hub nut with brakes applied. NOTE: Hub and driveshaft are splined together through knuckle (bearing) and retained by hub nut. 3. Raise and support vehicle, then remove front wheel and tire assembly. 4. Remove hub nut. Ensure splined driveshaft is free to separate from spline in hub during knuckle removal. A pulling force on shaft can separate inner CV joint. Tap lightly with brass drift, if required. 5. Disconnect tie rod end from steering arm with a suitable puller. 6. Disconnect brake hose retainer from strut damper. 7. Remove clamp bolt securing ball joint stud into steering knuckle, then brake caliper adapter screw and washer assemblies. 8. Support caliper with a piece of wire. Do not hang by brake hose. 9. Remove rotor, then separate ball joint stud from knuckle assembly. 10. Remove knuckle assembly from vehicle. Support driveshaft during knuckle removal. Do not permit driveshaft to hang after separating steering knuckle from vehicle. INSTALLATION 1. Place steering knuckle on lower ball joint stud and driveshaft through hub. 2. Install and tighten ball joint to steering knuckle clamp bolt to specifications. 3. Install tie rod end into steering arm and tighten nut to specifications. Install cotter pin. 4. Install rotor. 5. Install caliper over rotor and position adapter to steering knuckle. Install adapter to knuckle attaching bolts and tighten to specifications. 6. Attach brake hose retainer to strut damper and tighten attaching screw to specifications. 7. Install hub nut assembly as follows: a. With brakes applied, install hub nut and tighten to specifications. b. Install spring washer, locknut and new cotter pin. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Stabilizer Bar: Service and Repair Front Fig. 23 Stabilizer Bar Assembly REMOVAL 1. Raise and support vehicle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 6615 2. Remove nuts, bolts and retainers at control arms. 3. Remove crossmember clamp attaching bolts, then crossmember clamps. 4. Remove sway bar from vehicle. INSTALLATION 1. Position crossmember bushings on sway bar with curved surface up and split to front of vehicle. 2. Position bar assembly onto crossmember, then install clamps and attaching bolts. 3. Position retainers at control arms, then install bolts and attaching nuts. 4. Raise lower control arm to correct position, then tighten attaching bolts to specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 6616 Stabilizer Bar: Service and Repair Rear REMOVAL 1. Raise and support vehicle. Fig. 6 Rear Sway Bar Assembly 2. Remove lower two sway bar to link arm retaining bolts on both sides of vehicle. 3. Loosen, but do not remove four sway bar to bushing retainers to rear axle tube brackets. 4. Hold sway bar in place, then remove four loose bolts and remove sway bar. Remove link arms if needed. INSTALLATION 1. If link arms were removed, install retaining nuts but do not tighten. 2. Position axle to sway bar bushings on sway bar with slit in bushing facing up. 3. Install sway bar assembly onto rear axle but do not tighten bolts. 4. Install two lower link arm bolts to sway bar but do nut tighten bolts. 5. Lower vehicle, then tighten to specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest: > 021994 > Nov > 94 > Front Suspension - Rapping Noise On Bumps Strut / Shock Tower: Customer Interest Front Suspension - Rapping Noise On Bumps NO: 02-19-94 GROUP: Front Suspension DATE: Nov. 25, 1994 SUBJECT: Front Suspension Rapping Noise When Traveling Over Bumps THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-08-93 DATED OCT. 29, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 - **1995** (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A metal to metal rapping noise can be heard coming from the front suspension when traveling over bumps. DIAGNOSIS: With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If contact is evident, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves providing additional clearance between the front coil spring(s) and strut tower(s). 1. With the vehicle on a hoist, remove the front strut assembly(s). 2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against the sheetmetal of the strut tower, their contours match. 3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 in. (6 mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the reference. 4. Repair the paint of the reworked area both in the wheel well and the engine compartment as necessary. Use the paint manufacturer anti-corrosion recommendations. 5. Reinstall the strut assembly(s). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest: > 021994 > Nov > 94 > Front Suspension - Rapping Noise On Bumps > Page 6625 6. Use the proper procedure to set the front suspension camber to +0.3 degrees and toe adjustment 0.1 degree toe in. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 02-27-01-94 (One Side) 1.4 Hrs. 02-27-01-95 (Both Sides) 1.9 Hrs. FAILURE CODE: XX - Service Adjustments Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest: > 020893 > Oct > 93 > Front Coil Spring - Metallic Rapping Noise Strut / Shock Tower: Customer Interest Front Coil Spring - Metallic Rapping Noise NO.: 02-08-93 GROUP: Front Suspension DATE: Oct. 29, 1993 SUBJECT: Noise Due To Coil Spring To Strut Tower Contact MODELS: 1994 (AS) Grand Caravan/Caravan CV/Grand Voyager/Town & Country NOTE: THIS BULLETIN APPLIES TO LONG WHEEL BASE VEHICLES BUILT PRIOR TO 8/20/93 (MDH 0820xx). SYMPTOM/CONDITION: A metal to metal rapping noise can be heard coming from the front suspension when traveling over bumps. This noise is caused by the front coil spring(s) coming into contact with the strut tower(s). DIAGNOSIS: With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If contact is evident, perform the repair procedure. REPAIR PROCEDURE: This repair involves providing additional clearance between the front coil spring(s) and strut tower(s). 1. With the vehicle on a hoist, remove the front strut assembly(s) using the procedure outlined in the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105) beginning on page 2-8. 2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against the sheetmetal of the strut tower, their contours match. 3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 In. (6 mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the reference. 4. Repair the paint of the reworked area both in the wheel well and the engine compartment as necessary. Use the paint manufacturer anti-corrosion Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest: > 020893 > Oct > 93 > Front Coil Spring - Metallic Rapping Noise > Page 6630 recommendations. 5. Reinstall the strut assembly(s). 6. Use the procedure outlined in the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105) beginning on page 2-6 to set the front suspension camber to +0.3 degrees and toe adjustment 0.1 degree tow in. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 02-27-01-94 One Side 1.4 Hrs. 02-27-01-95 Both Sides 1.9 Hrs. FAILURE CODE: XX - Service Adjustments Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 021994 > Nov > 94 > Front Suspension - Rapping Noise On Bumps Strut / Shock Tower: All Technical Service Bulletins Front Suspension - Rapping Noise On Bumps NO: 02-19-94 GROUP: Front Suspension DATE: Nov. 25, 1994 SUBJECT: Front Suspension Rapping Noise When Traveling Over Bumps THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-08-93 DATED OCT. 29, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 - **1995** (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A metal to metal rapping noise can be heard coming from the front suspension when traveling over bumps. DIAGNOSIS: With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If contact is evident, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves providing additional clearance between the front coil spring(s) and strut tower(s). 1. With the vehicle on a hoist, remove the front strut assembly(s). 2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against the sheetmetal of the strut tower, their contours match. 3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 in. (6 mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the reference. 4. Repair the paint of the reworked area both in the wheel well and the engine compartment as necessary. Use the paint manufacturer anti-corrosion recommendations. 5. Reinstall the strut assembly(s). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 021994 > Nov > 94 > Front Suspension - Rapping Noise On Bumps > Page 6636 6. Use the proper procedure to set the front suspension camber to +0.3 degrees and toe adjustment 0.1 degree toe in. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 02-27-01-94 (One Side) 1.4 Hrs. 02-27-01-95 (Both Sides) 1.9 Hrs. FAILURE CODE: XX - Service Adjustments Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 240294 > Jan > 94 > A/C Hose Squeaking Noise Strut / Shock Tower: All Technical Service Bulletins A/C Hose - Squeaking Noise NO: 24-02-94 GROUP: Heat & A/C DATE: Jan. 14, 1994 SUBJECT: Squeak in Right Shock Tower Area MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: If a squeaking noise seems to be coming from the right shock tower, a possible cause is the right shock tower A/C hose support bracket. This should be checked prior to looking elsewhere on or in the shock tower. If the insulation foam between the bracket and hoses is mis-positioned or worn through, a squeak may occur under driving conditions. Inspect the hose and bracket area and relocate or replace the foam or bend the bracket to eliminate any metal-to-metal contact. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 020893 > Oct > 93 > Front Coil Spring - Metallic Rapping Noise Strut / Shock Tower: All Technical Service Bulletins Front Coil Spring - Metallic Rapping Noise NO.: 02-08-93 GROUP: Front Suspension DATE: Oct. 29, 1993 SUBJECT: Noise Due To Coil Spring To Strut Tower Contact MODELS: 1994 (AS) Grand Caravan/Caravan CV/Grand Voyager/Town & Country NOTE: THIS BULLETIN APPLIES TO LONG WHEEL BASE VEHICLES BUILT PRIOR TO 8/20/93 (MDH 0820xx). SYMPTOM/CONDITION: A metal to metal rapping noise can be heard coming from the front suspension when traveling over bumps. This noise is caused by the front coil spring(s) coming into contact with the strut tower(s). DIAGNOSIS: With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If contact is evident, perform the repair procedure. REPAIR PROCEDURE: This repair involves providing additional clearance between the front coil spring(s) and strut tower(s). 1. With the vehicle on a hoist, remove the front strut assembly(s) using the procedure outlined in the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105) beginning on page 2-8. 2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against the sheetmetal of the strut tower, their contours match. 3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 In. (6 mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the reference. 4. Repair the paint of the reworked area both in the wheel well and the engine compartment as necessary. Use the paint manufacturer anti-corrosion Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 020893 > Oct > 93 > Front Coil Spring - Metallic Rapping Noise > Page 6645 recommendations. 5. Reinstall the strut assembly(s). 6. Use the procedure outlined in the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105) beginning on page 2-6 to set the front suspension camber to +0.3 degrees and toe adjustment 0.1 degree tow in. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 02-27-01-94 One Side 1.4 Hrs. 02-27-01-95 Both Sides 1.9 Hrs. FAILURE CODE: XX - Service Adjustments Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Other Service Bulletins for Strut / Shock Tower: > 240294 > Jan > 94 > A/C Hose Squeaking Noise Strut / Shock Tower: All Technical Service Bulletins A/C Hose - Squeaking Noise NO: 24-02-94 GROUP: Heat & A/C DATE: Jan. 14, 1994 SUBJECT: Squeak in Right Shock Tower Area MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: If a squeaking noise seems to be coming from the right shock tower, a possible cause is the right shock tower A/C hose support bracket. This should be checked prior to looking elsewhere on or in the shock tower. If the insulation foam between the bracket and hoses is mis-positioned or worn through, a squeak may occur under driving conditions. Inspect the hose and bracket area and relocate or replace the foam or bend the bracket to eliminate any metal-to-metal contact. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 021994 > Nov > 94 > Front Suspension - Rapping Noise On Bumps Suspension Spring ( Coil / Leaf ): Customer Interest Front Suspension - Rapping Noise On Bumps NO: 02-19-94 GROUP: Front Suspension DATE: Nov. 25, 1994 SUBJECT: Front Suspension Rapping Noise When Traveling Over Bumps THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-08-93 DATED OCT. 29, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 - **1995** (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A metal to metal rapping noise can be heard coming from the front suspension when traveling over bumps. DIAGNOSIS: With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If contact is evident, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves providing additional clearance between the front coil spring(s) and strut tower(s). 1. With the vehicle on a hoist, remove the front strut assembly(s). 2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against the sheetmetal of the strut tower, their contours match. 3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 in. (6 mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the reference. 4. Repair the paint of the reworked area both in the wheel well and the engine compartment as necessary. Use the paint manufacturer anti-corrosion recommendations. 5. Reinstall the strut assembly(s). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 021994 > Nov > 94 > Front Suspension - Rapping Noise On Bumps > Page 6659 6. Use the proper procedure to set the front suspension camber to +0.3 degrees and toe adjustment 0.1 degree toe in. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 02-27-01-94 (One Side) 1.4 Hrs. 02-27-01-95 (Both Sides) 1.9 Hrs. FAILURE CODE: XX - Service Adjustments Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 233094 > Mar > 94 > Rear Leaf Springs - Floor Pan Ticking Noise Suspension Spring ( Coil / Leaf ): Customer Interest Rear Leaf Springs - Floor Pan Ticking Noise NO: 23-30-94 GROUP: Body DATE: Mar. 25, 1994 SUBJECT: Ticking Noise from Under Floor Pan MODELS: 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A ticking noise can be heard coming from under the floor pan near the area of the bases of the middle seat(s) while driving, but is more evident during cornering. DIAGNOSIS: Ensure the middle seats are properly latched in position. Test drive the vehicle and make cornering maneuvers or go over expansion strips in the road surface and listen for the sound. Perform the repair procedure if a ticking noise is heard. PARTS REQUIRED: AR 4318035 Mopar Spray Gasket Sealant REPAIR PROCEDURE: This bulletin involves applying a film between the floor pan and the front mounting bracket(s) for the rear leaf spring(s). 1. Raise the vehicle on an appropriate hoist. 2. Loosen and back out (without removing) the bolts securing the front mounting bracket of the leaf spring. 3. Spray Mopar Spray Gasket Sealant (P/N 4318035) between the mounting surface on the bottom of the vehicle and the front mounting bracket of the leaf spring. 4. Torque the attaching bolts of the front mounting bracket for the leaf spring to 45 ft. lbs. (115 N-m). 5. Repeat steps 1 through 4 for the opposite side if necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-30-35-90 0.2 Hrs. FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 020893 > Oct > 93 > Front Coil Spring - Metallic Rapping Noise Suspension Spring ( Coil / Leaf ): Customer Interest Front Coil Spring - Metallic Rapping Noise NO.: 02-08-93 GROUP: Front Suspension DATE: Oct. 29, 1993 SUBJECT: Noise Due To Coil Spring To Strut Tower Contact MODELS: 1994 (AS) Grand Caravan/Caravan CV/Grand Voyager/Town & Country NOTE: THIS BULLETIN APPLIES TO LONG WHEEL BASE VEHICLES BUILT PRIOR TO 8/20/93 (MDH 0820xx). SYMPTOM/CONDITION: A metal to metal rapping noise can be heard coming from the front suspension when traveling over bumps. This noise is caused by the front coil spring(s) coming into contact with the strut tower(s). DIAGNOSIS: With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If contact is evident, perform the repair procedure. REPAIR PROCEDURE: This repair involves providing additional clearance between the front coil spring(s) and strut tower(s). 1. With the vehicle on a hoist, remove the front strut assembly(s) using the procedure outlined in the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105) beginning on page 2-8. 2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against the sheetmetal of the strut tower, their contours match. 3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 In. (6 mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the reference. 4. Repair the paint of the reworked area both in the wheel well and the engine compartment as necessary. Use the paint manufacturer anti-corrosion Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 020893 > Oct > 93 > Front Coil Spring - Metallic Rapping Noise > Page 6668 recommendations. 5. Reinstall the strut assembly(s). 6. Use the procedure outlined in the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105) beginning on page 2-6 to set the front suspension camber to +0.3 degrees and toe adjustment 0.1 degree tow in. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 02-27-01-94 One Side 1.4 Hrs. 02-27-01-95 Both Sides 1.9 Hrs. FAILURE CODE: XX - Service Adjustments Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 021994 > Nov > 94 > Front Suspension - Rapping Noise On Bumps Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Front Suspension - Rapping Noise On Bumps NO: 02-19-94 GROUP: Front Suspension DATE: Nov. 25, 1994 SUBJECT: Front Suspension Rapping Noise When Traveling Over Bumps THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-08-93 DATED OCT. 29, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 - **1995** (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A metal to metal rapping noise can be heard coming from the front suspension when traveling over bumps. DIAGNOSIS: With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If contact is evident, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves providing additional clearance between the front coil spring(s) and strut tower(s). 1. With the vehicle on a hoist, remove the front strut assembly(s). 2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against the sheetmetal of the strut tower, their contours match. 3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 in. (6 mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the reference. 4. Repair the paint of the reworked area both in the wheel well and the engine compartment as necessary. Use the paint manufacturer anti-corrosion recommendations. 5. Reinstall the strut assembly(s). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 021994 > Nov > 94 > Front Suspension - Rapping Noise On Bumps > Page 6674 6. Use the proper procedure to set the front suspension camber to +0.3 degrees and toe adjustment 0.1 degree toe in. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 02-27-01-94 (One Side) 1.4 Hrs. 02-27-01-95 (Both Sides) 1.9 Hrs. FAILURE CODE: XX - Service Adjustments Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 233094 > Mar > 94 > Rear Leaf Springs - Floor Pan Ticking Noise Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Rear Leaf Springs - Floor Pan Ticking Noise NO: 23-30-94 GROUP: Body DATE: Mar. 25, 1994 SUBJECT: Ticking Noise from Under Floor Pan MODELS: 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A ticking noise can be heard coming from under the floor pan near the area of the bases of the middle seat(s) while driving, but is more evident during cornering. DIAGNOSIS: Ensure the middle seats are properly latched in position. Test drive the vehicle and make cornering maneuvers or go over expansion strips in the road surface and listen for the sound. Perform the repair procedure if a ticking noise is heard. PARTS REQUIRED: AR 4318035 Mopar Spray Gasket Sealant REPAIR PROCEDURE: This bulletin involves applying a film between the floor pan and the front mounting bracket(s) for the rear leaf spring(s). 1. Raise the vehicle on an appropriate hoist. 2. Loosen and back out (without removing) the bolts securing the front mounting bracket of the leaf spring. 3. Spray Mopar Spray Gasket Sealant (P/N 4318035) between the mounting surface on the bottom of the vehicle and the front mounting bracket of the leaf spring. 4. Torque the attaching bolts of the front mounting bracket for the leaf spring to 45 ft. lbs. (115 N-m). 5. Repeat steps 1 through 4 for the opposite side if necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-30-35-90 0.2 Hrs. FAILURE CODE: 68 - Noisy Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 020893 > Oct > 93 > Front Coil Spring - Metallic Rapping Noise Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Front Coil Spring - Metallic Rapping Noise NO.: 02-08-93 GROUP: Front Suspension DATE: Oct. 29, 1993 SUBJECT: Noise Due To Coil Spring To Strut Tower Contact MODELS: 1994 (AS) Grand Caravan/Caravan CV/Grand Voyager/Town & Country NOTE: THIS BULLETIN APPLIES TO LONG WHEEL BASE VEHICLES BUILT PRIOR TO 8/20/93 (MDH 0820xx). SYMPTOM/CONDITION: A metal to metal rapping noise can be heard coming from the front suspension when traveling over bumps. This noise is caused by the front coil spring(s) coming into contact with the strut tower(s). DIAGNOSIS: With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If contact is evident, perform the repair procedure. REPAIR PROCEDURE: This repair involves providing additional clearance between the front coil spring(s) and strut tower(s). 1. With the vehicle on a hoist, remove the front strut assembly(s) using the procedure outlined in the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105) beginning on page 2-8. 2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against the sheetmetal of the strut tower, their contours match. 3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 In. (6 mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the reference. 4. Repair the paint of the reworked area both in the wheel well and the engine compartment as necessary. Use the paint manufacturer anti-corrosion Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 020893 > Oct > 93 > Front Coil Spring - Metallic Rapping Noise > Page 6683 recommendations. 5. Reinstall the strut assembly(s). 6. Use the procedure outlined in the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105) beginning on page 2-6 to set the front suspension camber to +0.3 degrees and toe adjustment 0.1 degree tow in. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 02-27-01-94 One Side 1.4 Hrs. 02-27-01-95 Both Sides 1.9 Hrs. FAILURE CODE: XX - Service Adjustments Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Coil Spring Replace Suspension Spring ( Coil / Leaf ): Service and Repair Front Coil Spring Replace Fig. 11 Strut Damper Mount Assembly 1. Remove strut damper assembly as outlined under Strut Damper Assembly Replacement. 2. Compress coil spring using suitable tool. 3. Remove strut rod nut while holding strut rod to prevent rotation. 4. Remove mount assembly. 5. Remove coil spring from strut damper. 6. Inspect mount assembly for deterioration of rubber isolator, retainers for cracks and distortion, and bearings for blinding. 7. Install dust shield, jounce bumper, spacer and seat to top of spring. Mount assembly to rod, then install retainer and rod nut. 8. Position spring retainer alignment notch parallel to damper lower attaching bracket. 9. Tighten strut rod nut to specifications, using suitable tool, then release spring compressor. 10. With weight of vehicle off front wheels, turn both strut rod and strut rod nut in same direction until upper spring seat is properly positioned, then recheck torque of strut rod nut. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Coil Spring Replace > Page 6686 Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Replacement Fig. 1 Rear Axle & Suspension Assembly (FWD) FWD models Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Coil Spring Replace > Page 6687 Fig. 2 Rear Axle & Suspension Assembly (RWD) AWD models REMOVAL 1. Raise and support vehicle, then position suitable floor jack below axle assembly and raise axle assembly to relieve weight on rear springs. 2. Disconnect height sensor actuator assembly, then lower ends of rear shock absorbers at axle brackets. 3. Remove U-bolt attaching nuts and washers, then U-bolt. 4. Disconnect and lower rear axle assembly, allowing rear spring to hang free. 5. Remove four attaching bolts from front spring hanger. 6. Remove rear spring shackle attaching nuts and plate, then shackle from spring. 7. Remove front pivot bolt from front spring hanger. 8. Remove springs from vehicle. INSTALLATION 1. Assemble shackle, bushings and plate on rear of spring and rear spring hanger, then install shackle bolt. Do not tighten nut at this point. 2. Assemble front spring hanger to front of spring eye, then install pivot bolt. Do not tighten nut at this point. Pivot bolt must face inboard to prevent structural damage during installation of spring. 3. Raise front spring, then install four hanger attaching bolts. Tighten bolts to specifications, then connect actuator assembly. 4. Raise axle assembly with axle centered below spring center bolt, then install U-bolt and washer. Tighten U-bolt attaching nut to specifications. 5. Install shock absorbers and attaching nuts. Do not tighten nuts at this point. 6. Lower vehicle to floor, allowing full weight of vehicle on wheels, then tighten following fasteners to specifications: front pivot bolt, shackle nuts and shock absorber bolts. 7. Connect rear brake proportioning valve spring. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement Suspension Strut / Shock Absorber: Service and Repair Shock Absorber Replacement 1. Raise and support vehicle. 2. Support axle with a suitable jack stand. 3. Remove lower shock bolt. 4. While holding shock, remove upper shock bolt. 5. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 6692 Suspension Strut / Shock Absorber: Service and Repair Replacement Fig. 28 Strut Damper Assembly Removal REMOVAL 1. Raise and support vehicle, then remove front wheels. 2. Mark position of camber adjusting cam, then remove camber adjusting bolt, through bolt and brake hose to damper bracket retaining screw. 3. Remove strut damper to fender shield mounting nut and washer assemblies. 4. Remove strut damper from vehicle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 6693 Fig. 29 Strut Damper Assembly Installation INSTALLATION 1. Position strut assembly into fender reinforcement, then install retaining nut and washer assemblies. Tighten retaining nut to specifications. 2. Position steering knuckle into strut, then install washer plate, cam bolts and knuckle bolts. 3. Attach brake hose retainers to damper. Tighten to specifications. 4. Index cam bolt to alignment mark made during removal. 5. Position a 4 inch or larger C-clamp on steering knuckle and strut, then tighten clamp just enough to eliminate any looseness between strut and knuckle. Tighten cam bolts to specifications. 6. Remove C-clamp, then install wheel and tire assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments Fig. 3 Wheel bearing assembly 1. Raise and support rear of vehicle. 2. Tighten adjusting nut to specifications, while rotating wheel. 3. Stop wheel and loosen adjusting nut by 1/4 turn. 4. Tighten adjusting nut finger tight. Endplay should be .001-.003 inch. 5. Install castle lock with slots aligned with cotter pin hole. 6. Install cotter pin and grease cap. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front This hub and bearing assembly is being used on certain extended wheelbase Caravan, Voyager and Mini Ram Vans. This unit is serviced as a complete assembly, and is attached to the steering knuckle by four mounting screws that are removed from the rear of the knuckle assembly. Remove 1. Remove cotter pin, nut lock, and spring washer. 2. Loosen hub nut while the vehicle is on the floor with the brakes applied. The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut. 3. Raise vehicle. 4. Remove hub nut, washer, and wheel and tire assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6699 5. Disconnect tie rod end from steering arm with Tool C-3894-A. 6. Remove clamp bolt securing ball joint stud into steering knuckle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6700 7. Remove caliper guide pins and separate caliper assembly from braking disc. SUPPORT CALIPER WITH WIRE HOOK AND NOT BY HYDRAULIC HOSE. Remove braking disc. 8. Separate ball joint stud from knuckle assembly. Pull knuckle assembly out and away from driveshaft. NOTE: Care must be taken not to separate the Inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint, driveshaft must be supported. 9. Remove the four hub and bearing assembly mounting screws from rear of steering knuckle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6701 10. Remove hub and bearing assembly. Replacement of the grease seal is recommended whenever this service is performed. Installation 1. Install new hub and bearing assembly and tighten screws in a criss-cross pattern to 45 ft.lbs. (65 Nm.). CAUTION: Knuckle and bearing mounting surfaces must be smooth and completely free of foreign material or nicks. 2. Position new seal in recess and assemble installer Tool C-4698 tool is provided with a handle and dual purpose drive head for installing seal into knuckle and (head reversed) for installing wear sleeve into C/V joint housing). 3. Assemble tool and install seal. CAUTION: During any service procedures where knuckle and driveshaft are separated, thoroughly clean seal and wear sleeve and relubricate BOTH components. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6702 4. Lubricate the full circumference of the seal (and wear sleeve) with MOPAR Multi-Purpose Lubricant or equivalent. 5. Install driveshaft through hub, then install steering knuckle assembly on lower control arm ball joint stud. 6. Install original (or equivalent) ball joint to knuckle clamp bolt, torque to 95 Nm (70 ft.lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6703 7. Install tie rod end into steering arm, tighten nut to 47 Nm (35 ft.lbs.) torque and install cotter key. 8. Install braking disc. 9. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment on knuckle assembly. Install guide pins and tighten to 25-35 Nm (18-26 ft.lbs.). When installing guide pins, use extreme caution not to cross the threads. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6704 10. Install washer and hub nut after cleaning foreign matter from threads. 11. With brakes applied, tighten nut to 180 ft.lbs. (244 Nm). 12. Install spring washer, nut lock, and new cotter pin. Wrap cotter pin prongs tightly around nut lock. 13. Install wheel and tire assembly. Tighten wheel nuts to 85 ft.lbs. (115 Nm). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6705 Wheel Bearing: Service and Repair Rear REMOVAL AND INSTALLATION 1. Remove the rear tire and wheel assembly. 2. Remove grease cap, cotter pin, nut lock, nut, thrust washer and outer wheel bearing. 3. Carefully slide hub or drum from spindle. Do not drag inner bearing or grease seal over stub axle (thread, bearing, and oil seal may be damaged.) Using an appropriate tool remove the grease seal and inner bearing from the drum or hub. Discard grease seal, a new seal should be used when reinstalling the inner bearing. 4. Thoroughly clean all old grease from the outer and inner bearings, bearing cups and hub cavity. To clean bearings, soak them in an appropriate cleaning solvent. Strike the flat surface of the bearing inner race against a hardwood block several times, to loosen grease. Immerse the bearings in solvent between blows to jar loose and wash old particles of hardened grease from bearings. Repeat this operation until bearings are clean. Bearings can be dried using compressed air but do not spin the bearings. After cleaning, oil the bearings with engine oil. Insert the bearing into its appropriate cup, apply pressure to the bearing while rotating it to test them for pitting and roughness. Replace all worn or defective bearings. If bearing shows signs of pitting or roughness they should be replaced. Bearings must be replaced as a set, both the cup and the bearing need to be replaced at the same time. If bearings are suitable for further use, remove engine oil from bearings using appropriate solvent and dry bearings. Repack the bearings using a Multi-Purpose NLGI. Grade 2 EP Grease such as Mopar® or equivalent, and place them in a clean covered container until ready for installation. If a bearing packer is not available, hand pack grease into all cavities between bearing cage and rollers. 5. If bearings and cups are to be replaced, remove cups from the drum or hub using a brass drift or suitable remover. 6. Replace bearing cups with appropriate installing tool. 7. Install inner bearing in grease coated hub and bearing cup, and install new grease seals using the appropriate seal installer. 8. Coat outer hub cavity and cup with grease. 9. Before installing hub or drum assembly, inspect stub axle and seal surface for burrs or roughness, and smooth out all rough surfaces. 10. Coat the stub axle with Multi-Purpose NLGI, Grade 2 EP grease or equivalent. 11. Carefully slide the hub of drum assembly onto the stub axle. Do not drag seal or inner bearing over the threaded area of the stub axle. 12. Install outer bearing, thrust washer and nut. 13. Tighten the wheel bearing adjusting nut to 27 to 34 Nm (240 to 300 in.lbs.) while rotating hub or drum assembly. This seats the bearings. 14. Back off adjusting nut 1/4 turn (90°) then tighten adjusting nut only finger tight. 15. Position the nut lock over the bearing adjusting nut with one pair of slots in line with the cotter pin hole in the stub axle. Install cotter pin. 16. Install the grease caps and the wheel and tire assemblies. Tighten wheel stud nuts to 115 Nm (85 ft. lbs.) on all models. Reinstall wheel covers if so equipped. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Front Wheel Hub: Service and Repair Front This hub and bearing assembly is being used on certain extended wheelbase Caravan, Voyager and Mini Ram Vans. This unit is serviced as a complete assembly, and is attached to the steering knuckle by four mounting screws that are removed from the rear of the knuckle assembly. Remove 1. Remove cotter pin, nut lock, and spring washer. 2. Loosen hub nut while the vehicle is on the floor with the brakes applied. The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut. 3. Raise vehicle. 4. Remove hub nut, washer, and wheel and tire assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Front > Page 6710 5. Disconnect tie rod end from steering arm with Tool C-3894-A. 6. Remove clamp bolt securing ball joint stud into steering knuckle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Front > Page 6711 7. Remove caliper guide pins and separate caliper assembly from braking disc. SUPPORT CALIPER WITH WIRE HOOK AND NOT BY HYDRAULIC HOSE. Remove braking disc. 8. Separate ball joint stud from knuckle assembly. Pull knuckle assembly out and away from driveshaft. NOTE: Care must be taken not to separate the Inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint, driveshaft must be supported. 9. Remove the four hub and bearing assembly mounting screws from rear of steering knuckle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Front > Page 6712 10. Remove hub and bearing assembly. Replacement of the grease seal is recommended whenever this service is performed. Installation 1. Install new hub and bearing assembly and tighten screws in a criss-cross pattern to 45 ft.lbs. (65 Nm.). CAUTION: Knuckle and bearing mounting surfaces must be smooth and completely free of foreign material or nicks. 2. Position new seal in recess and assemble installer Tool C-4698 tool is provided with a handle and dual purpose drive head for installing seal into knuckle and (head reversed) for installing wear sleeve into C/V joint housing). 3. Assemble tool and install seal. CAUTION: During any service procedures where knuckle and driveshaft are separated, thoroughly clean seal and wear sleeve and relubricate BOTH components. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Front > Page 6713 4. Lubricate the full circumference of the seal (and wear sleeve) with MOPAR Multi-Purpose Lubricant or equivalent. 5. Install driveshaft through hub, then install steering knuckle assembly on lower control arm ball joint stud. 6. Install original (or equivalent) ball joint to knuckle clamp bolt, torque to 95 Nm (70 ft.lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Front > Page 6714 7. Install tie rod end into steering arm, tighten nut to 47 Nm (35 ft.lbs.) torque and install cotter key. 8. Install braking disc. 9. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment on knuckle assembly. Install guide pins and tighten to 25-35 Nm (18-26 ft.lbs.). When installing guide pins, use extreme caution not to cross the threads. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Front > Page 6715 10. Install washer and hub nut after cleaning foreign matter from threads. 11. With brakes applied, tighten nut to 180 ft.lbs. (244 Nm). 12. Install spring washer, nut lock, and new cotter pin. Wrap cotter pin prongs tightly around nut lock. 13. Install wheel and tire assembly. Tighten wheel nuts to 85 ft.lbs. (115 Nm). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Front > Page 6716 Wheel Hub: Service and Repair Rear REMOVAL AND INSTALLATION 1. Remove the rear tire and wheel assembly. 2. Remove grease cap, cotter pin, nut lock, nut, thrust washer and outer wheel bearing. 3. Carefully slide hub or drum from spindle. Do not drag inner bearing or grease seal over stub axle (thread, bearing, and oil seal may be damaged.) Using an appropriate tool remove the grease seal and inner bearing from the drum or hub. Discard grease seal, a new seal should be used when reinstalling the inner bearing. 4. Thoroughly clean all old grease from the outer and inner bearings, bearing cups and hub cavity. To clean bearings, soak them in an appropriate cleaning solvent. Strike the flat surface of the bearing inner race against a hardwood block several times, to loosen grease. Immerse the bearings in solvent between blows to jar loose and wash old particles of hardened grease from bearings. Repeat this operation until bearings are clean. Bearings can be dried using compressed air but do not spin the bearings. After cleaning, oil the bearings with engine oil. Insert the bearing into its appropriate cup, apply pressure to the bearing while rotating it to test them for pitting and roughness. Replace all worn or defective bearings. If bearing shows signs of pitting or roughness they should be replaced. Bearings must be replaced as a set, both the cup and the bearing need to be replaced at the same time. If bearings are suitable for further use, remove engine oil from bearings using appropriate solvent and dry bearings. Repack the bearings using a Multi-Purpose NLGI. Grade 2 EP Grease such as Mopar® or equivalent, and place them in a clean covered container until ready for installation. If a bearing packer is not available, hand pack grease into all cavities between bearing cage and rollers. 5. If bearings and cups are to be replaced, remove cups from the drum or hub using a brass drift or suitable remover. 6. Replace bearing cups with appropriate installing tool. 7. Install inner bearing in grease coated hub and bearing cup, and install new grease seals using the appropriate seal installer. 8. Coat outer hub cavity and cup with grease. 9. Before installing hub or drum assembly, inspect stub axle and seal surface for burrs or roughness, and smooth out all rough surfaces. 10. Coat the stub axle with Multi-Purpose NLGI, Grade 2 EP grease or equivalent. 11. Carefully slide the hub of drum assembly onto the stub axle. Do not drag seal or inner bearing over the threaded area of the stub axle. 12. Install outer bearing, thrust washer and nut. 13. Tighten the wheel bearing adjusting nut to 27 to 34 Nm (240 to 300 in.lbs.) while rotating hub or drum assembly. This seats the bearings. 14. Back off adjusting nut 1/4 turn (90°) then tighten adjusting nut only finger tight. 15. Position the nut lock over the bearing adjusting nut with one pair of slots in line with the cotter pin hole in the stub axle. Install cotter pin. 16. Install the grease caps and the wheel and tire assemblies. Tighten wheel stud nuts to 115 Nm (85 ft. lbs.) on all models. Reinstall wheel covers if so equipped. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Locations Fig. 1 Caravan, Town & Country & Voyager Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. Technical Service Bulletin # 22-03-99 Date: 990423 Tires/Wheels - Smooth Road Vibration/Shake/Wobble. NUMBER: 22-03-99 GROUP: Wheels & Tires DATE: April 23, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: Smooth Road Vibration/Shake/Wobble OVERVIEW: This bulletin involves diagnosis and correction information for vehicles with a smooth road high-speed vibration or shake condition. Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph) is addressed by TSB 22-02-99. Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with 3.0L engine and 31TH transaxle is addressed by TSB 19-04-97. High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph). MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) EQUIPMENT REQUIRED: Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer (Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper POLICY: Information Only Diagnosis and Correction Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a hoist and inspect the following items: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6729 VISUAL INSPECTION Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road surface with all accessories turned off. Correct any obvious safety related items identified during the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components. If the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration problem is still present make the following checks: ^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the Service Manual. ^ If the vibration does not change while coasting then the problem may be caused by tires, wheels or suspension. ^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of rotating components (tires, wheels, half shafts, drums or rotors). ^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel assembly run out. ^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel assembly. ^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer to the Service Manual. ^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may be caused by high 1st order tire/wheel assembly excitation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6730 ON CAR TIRE/WHEEL ASSEMBLY RUNOUT After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration is still present and it was determined that the vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure. Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of reducing runout. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6731 TIRE/WHEEL MATCH MOUNTING Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6732 WHEEL RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6733 WHEEL BORE PILOT DIAMETERS Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6734 HUB WHEEL PILOT DIAMETER Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6735 HUB WHEEL PILOT RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6736 WHEEL MOUNTING SURFACE LATERAL RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. Technical Service Bulletin # 22-03-99 Date: 990423 Tires/Wheels - Smooth Road Vibration/Shake/Wobble. NUMBER: 22-03-99 GROUP: Wheels & Tires DATE: April 23, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: Smooth Road Vibration/Shake/Wobble OVERVIEW: This bulletin involves diagnosis and correction information for vehicles with a smooth road high-speed vibration or shake condition. Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph) is addressed by TSB 22-02-99. Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with 3.0L engine and 31TH transaxle is addressed by TSB 19-04-97. High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph). MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) EQUIPMENT REQUIRED: Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer (Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper POLICY: Information Only Diagnosis and Correction Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a hoist and inspect the following items: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6742 VISUAL INSPECTION Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road surface with all accessories turned off. Correct any obvious safety related items identified during the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components. If the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration problem is still present make the following checks: ^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the Service Manual. ^ If the vibration does not change while coasting then the problem may be caused by tires, wheels or suspension. ^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of rotating components (tires, wheels, half shafts, drums or rotors). ^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel assembly run out. ^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel assembly. ^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer to the Service Manual. ^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may be caused by high 1st order tire/wheel assembly excitation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6743 ON CAR TIRE/WHEEL ASSEMBLY RUNOUT After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration is still present and it was determined that the vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure. Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of reducing runout. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6744 TIRE/WHEEL MATCH MOUNTING Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6745 WHEEL RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6746 WHEEL BORE PILOT DIAMETERS Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6747 HUB WHEEL PILOT DIAMETER Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6748 HUB WHEEL PILOT RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6749 WHEEL MOUNTING SURFACE LATERAL RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout Tires: All Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake Tires: All Technical Service Bulletins Tires/Wheels - Smooth Road Vibration/Shake NO: 22-02-94 GROUP: Wheels & Tires DATE: Feb.18, 1994 SUBJECT: Smooth Road Vibration/Shake MODELS: 1992 - 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: A smooth road vibration/shake condition may be observed on smooth roads as: - Low speed lateral wobble of the body (0-30 MPH) - Steering wheel/seat/floor pan vibration at high speeds (60+ MPH) Use the following flow chart for diagnosis and correction: DYNAMIC CHECK Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of vibration/shake condition. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 6758 VISUAL INSPECTION (See illustration) TIRE/WHEEL/HUB RUNOUT CHECKS NOTE: ENSURE THE WHEEL BEARINGS ARE PROPERLY ADJUSTED BEFORE PROCEEDING. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 6759 Use a dial indicator to check the radial and lateral tire/wheel runouts on vehicle (refer to Figure 1). Mark the point of maximum radial and lateral runout on the tires/wheels. SPECIFICATIONS: Radial runout: 0.030 in. (0.762 mm) or LESS Lateral runout: 0.030 in. (0.762 mm) or LESS Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 6760 Mark the tire AND wheel at the point of highest runout. Remove the tire from the wheel and check the wheel runouts (check BOTH sides of the wheel at the bead seats (refer to Figure 2) with wheel mounted on an off car balancer. SPECIFICATIONS: Radial runout: 0.030 in. (0.762 mm) or LESS Lateral runout: 0.030 in. (0.762 mm) or LESS NOTE: HUB MEASUREMENTS APPLY TO FRONT HUBS ONLY ON FRONT WHEEL DRIVE (FWD) VEHICLES AND TO FRONT AND REAR HUBS ON ALL WHEEL DRIVE (AWD) VEHICLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 6761 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 6762 Measure hub wheel pilot diameter (refer to Figure 4). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout Tires: All Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake Tires: All Technical Service Bulletins Tires/Wheels - Smooth Road Vibration/Shake NO: 22-02-94 GROUP: Wheels & Tires DATE: Feb.18, 1994 SUBJECT: Smooth Road Vibration/Shake MODELS: 1992 - 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: A smooth road vibration/shake condition may be observed on smooth roads as: - Low speed lateral wobble of the body (0-30 MPH) - Steering wheel/seat/floor pan vibration at high speeds (60+ MPH) Use the following flow chart for diagnosis and correction: DYNAMIC CHECK Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of vibration/shake condition. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 6772 VISUAL INSPECTION (See illustration) TIRE/WHEEL/HUB RUNOUT CHECKS NOTE: ENSURE THE WHEEL BEARINGS ARE PROPERLY ADJUSTED BEFORE PROCEEDING. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 6773 Use a dial indicator to check the radial and lateral tire/wheel runouts on vehicle (refer to Figure 1). Mark the point of maximum radial and lateral runout on the tires/wheels. SPECIFICATIONS: Radial runout: 0.030 in. (0.762 mm) or LESS Lateral runout: 0.030 in. (0.762 mm) or LESS Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 6774 Mark the tire AND wheel at the point of highest runout. Remove the tire from the wheel and check the wheel runouts (check BOTH sides of the wheel at the bead seats (refer to Figure 2) with wheel mounted on an off car balancer. SPECIFICATIONS: Radial runout: 0.030 in. (0.762 mm) or LESS Lateral runout: 0.030 in. (0.762 mm) or LESS NOTE: HUB MEASUREMENTS APPLY TO FRONT HUBS ONLY ON FRONT WHEEL DRIVE (FWD) VEHICLES AND TO FRONT AND REAR HUBS ON ALL WHEEL DRIVE (AWD) VEHICLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 6775 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 6776 Measure hub wheel pilot diameter (refer to Figure 4). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels Wheels: Recalls Recall - Stamped Steel Road Wheels No. 603 January, 1994 To: All Dodge and Chrysler-Plymouth Dealers Subject: Safety Recall # 603 -- Stamped Steel Road Wheels Models: 1994 Model Year Dodge Grand Caravan, Plymouth Grand Voyager and Chrysler Town and Country Vehicles Built on September 23 and 24, 1993 and Equipped with 15" Stamped Steel Wheels and/or a 15" Full Size Stamped Steel Spare. The nut seat of the stamped steel road wheel may be misformed and result in the loss of lug nut torque retention. To correct the condition, all wheels must be inspected for an "M1" manufacturing plant code and all suspect wheels must be replaced. Less than 100 vehicles are involved in this recall. IMPORTANT: Some of the involved vehicles may be in dealer inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by Certified Mail. Important: Dealer notification by Certified Mail is required by federal law for all safety recalls. Responsible dealership personnel should be instructed to sign for this Certified Mail without hesitation as it concerns urgent safety recall information. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. All dealers: Each Dodge and Chrysler-Plymouth dealer will receive a copy of this dealer recall notification letter by Compak mail. DIAL System Function 70 All involved vehicles will be entered to DIAL System Function 70 at the time of recall implementation for dealer inquiry by VIN as needed. Parts Important: Due to the small number of involved vehicles and the unknown number of wheels required for each vehicle, no parts will be distributed initially to dealers. Dealers are requested to order parts only to support scheduled repairs. Wheel Packages, Recall PN C3905750, may be ordered at dealer cost to support customer demand. Owners were requested to inspect their vehicle to determine the number of replacement wheels required. Dealers should inquire if the owner performed the inspection and order the required parts when scheduling the service appointment. Each parts package contains the components (see illustration). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 6785 Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to inspect wheels for the suspect manufacturing plant code and/or schedule appointments for the service with their dealers at the earliest possible date. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure A. Inspect Wheel Manufacturing Plant Code: NOTE: Vehicle may have one, four or five wheels to be inspected. A1. FOR VEHICLES EQUIPPED WITH 15" STAMPED STEEL WHEELS (Sales Code WCF): a. Remove all wheel covers. b. Inspect wheel manufacturing plant code located above valve stem (Figure 1). NOTE: Manufacturing plant code may be covered by a green sticker. Remove and discard sticker as necessary. A2. FOR VEHICLES EQUIPPED WITH 15" FULL SIZE STAMPED STEEL SPARE (Sales Code -TBB): a. Gain access to spare. b. Inspect wheel manufacturing plant code located above valve stem (Figure 1). NOTE: Manufacturing plant code may be covered by a green sticker. Remove and discard sticker as necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 6786 A3. If any of the wheels inspected contain a Manufacturing Plant Code of M1, replace the affected wheel as instructed in Section B. If none of the wheels have the M1 plant code, reinstall wheel covers and/or secure spare, no further action is required. NOTE: Replace only those wheels having the M1 plant code. B. Replace Wheel: B1. Remove all wheels with suspect M1 plant code. Discard lug nuts. B2. Remove tire(s) from wheel(s). Set wheel(s) aside for return to Warranty Material Return Center. B3. Install supplied valve stem(s). B4. Mount and balance tire(s) on supplied wheel(s). B5. Install wheel and tire assembly on vehicle using supplied lug nuts. Tighten lug nuts to 95 ft.lbs. (130 N-m) torque. B6. Reinstall wheel cover(s) and/or secure spare. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances (see illustration). Add the cost of any recall parts packages used plus applicable dealer allowance to your claim. Parts Return Removed wheels must be returned to the Warranty Material Return Center. Note: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation 429-10-04 P.O. Box 1919 Detroit, Michigan 48231-1919 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 6787 SAFETY RECALL -- Stamped Steel Road Wheels Dear Chrysler Corporation Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1994 model Dodge Grand Caravan, Chrysler Town & Country and Plymouth Grand Voyager vehicles. The lug nuts attaching the stamped steel road wheels may loosen and result in a wheel becoming loose. This could result in an accident without prior warning. Your vehicle, identified on the enclosed form, is affected. For this reason we ask that you arrange for service to correct the condition without delay. The service and required parts as described in this letter will be provided free of charge. The stamped steel road wheel lug nut seats may have been misformed with an incorrect taper, which can result in loosening of the lug nuts. These wheels were used on vehicles equipped with 15" wheels with full wheel covers and also for 15" full size spare tires. You may inspect for suspect wheels yourself. Please refer to the instructions on the reverse side of this letter for details. If no suspect wheels are found, no further action is necessary. Please mark "INSPECTED -- OK" on the pre-addressed Vehicle Disposition Form portion of the enclosed owner notification form and put it in the mail. No postage is required. If you prefer not to do the inspection yourself, your dealer will do the inspection for you. To correct the condition, your dealer will inspect the manufacturing plant code of all steel wheels and replace any suspect wheels. The inspection will take less than one-half hour to complete. However, additional time may be required depending on how many wheels require replacement and how dealer appointments are scheduled and processed. To obtain this free service: ^ Contact your dealer as soon as possible to schedule an appointment for the service. If you performed the wheel inspection, be sure to inform your dealer of the number of suspect wheels found on your vehicle so the proper quantity of replacement wheels is ordered prior to your service appointment. ^ Take the enclosed Owner Notification Form with you at the time of your appointment and give it to your dealer. The form identifies the vehicle and the service that is required. If you have any problem obtaining the needed repair, please call the Chrysler Customer Center, toll free, at (800) 992-1997. A representative will assist you in getting your vehicle repaired. We regret any inconvenience which this action may cause you. However, we are concerned about your safety. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington D.C. area residents may call 366-0123.) Thank you for your attention to this important matter. STAMPED STEEL WHEEL INSPECTION INSTRUCTIONS 1994 DODGE GRAND CARAVAN, PLYMOUTH GRAND VOYAGER AND CHRYSLER TOWN & COUNTRY FOR VEHICLES EQUIPPED WITH 15" STAMPED STEEL WHEELS: ^ Remove all wheel covers. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 6788 ^ Inspect wheel manufacturing plant code located above valve stem as shown. ^ Reinstall wheel covers. FOR VEHICLES EQUIPPED WITH A 15" STAMPED STEEL WHEEL FULL SIZE SPARE: Gain access to spare following the instructions in your Owner's Manual. Inspect wheel manufacturing plant code located above valve stem as shown. If any of the wheels inspected contain a manufacturing plant code of M1, make an appointment with your dealer to have the suspect wheel(s) replaced. NOTE: Plant code may be covered by a green sticker. Remove and discard sticker as necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. Technical Service Bulletin # 22-03-99 Date: 990423 Tires/Wheels - Smooth Road Vibration/Shake/Wobble. NUMBER: 22-03-99 GROUP: Wheels & Tires DATE: April 23, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: Smooth Road Vibration/Shake/Wobble OVERVIEW: This bulletin involves diagnosis and correction information for vehicles with a smooth road high-speed vibration or shake condition. Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph) is addressed by TSB 22-02-99. Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with 3.0L engine and 31TH transaxle is addressed by TSB 19-04-97. High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph). MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) EQUIPMENT REQUIRED: Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer (Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper POLICY: Information Only Diagnosis and Correction Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a hoist and inspect the following items: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6794 VISUAL INSPECTION Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road surface with all accessories turned off. Correct any obvious safety related items identified during the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components. If the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration problem is still present make the following checks: ^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the Service Manual. ^ If the vibration does not change while coasting then the problem may be caused by tires, wheels or suspension. ^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of rotating components (tires, wheels, half shafts, drums or rotors). ^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel assembly run out. ^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel assembly. ^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer to the Service Manual. ^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may be caused by high 1st order tire/wheel assembly excitation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6795 ON CAR TIRE/WHEEL ASSEMBLY RUNOUT After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration is still present and it was determined that the vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure. Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of reducing runout. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6796 TIRE/WHEEL MATCH MOUNTING Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6797 WHEEL RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6798 WHEEL BORE PILOT DIAMETERS Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6799 HUB WHEEL PILOT DIAMETER Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6800 HUB WHEEL PILOT RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6801 WHEEL MOUNTING SURFACE LATERAL RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. Technical Service Bulletin # 22-03-99 Date: 990423 Tires/Wheels - Smooth Road Vibration/Shake/Wobble. NUMBER: 22-03-99 GROUP: Wheels & Tires DATE: April 23, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: Smooth Road Vibration/Shake/Wobble OVERVIEW: This bulletin involves diagnosis and correction information for vehicles with a smooth road high-speed vibration or shake condition. Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph) is addressed by TSB 22-02-99. Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with 3.0L engine and 31TH transaxle is addressed by TSB 19-04-97. High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph). MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) EQUIPMENT REQUIRED: Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer (Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper POLICY: Information Only Diagnosis and Correction Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a hoist and inspect the following items: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6807 VISUAL INSPECTION Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road surface with all accessories turned off. Correct any obvious safety related items identified during the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components. If the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration problem is still present make the following checks: ^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the Service Manual. ^ If the vibration does not change while coasting then the problem may be caused by tires, wheels or suspension. ^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of rotating components (tires, wheels, half shafts, drums or rotors). ^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel assembly run out. ^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel assembly. ^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer to the Service Manual. ^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may be caused by high 1st order tire/wheel assembly excitation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6808 ON CAR TIRE/WHEEL ASSEMBLY RUNOUT After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration is still present and it was determined that the vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure. Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of reducing runout. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6809 TIRE/WHEEL MATCH MOUNTING Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6810 WHEEL RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6811 WHEEL BORE PILOT DIAMETERS Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6812 HUB WHEEL PILOT DIAMETER Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6813 HUB WHEEL PILOT RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6814 WHEEL MOUNTING SURFACE LATERAL RUNOUT Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-01-97 > Jun > 97 > Tire & Wheel - Runout Wheels: All Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake Wheels: All Technical Service Bulletins Tires/Wheels - Smooth Road Vibration/Shake NO: 22-02-94 GROUP: Wheels & Tires DATE: Feb.18, 1994 SUBJECT: Smooth Road Vibration/Shake MODELS: 1992 - 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: A smooth road vibration/shake condition may be observed on smooth roads as: - Low speed lateral wobble of the body (0-30 MPH) - Steering wheel/seat/floor pan vibration at high speeds (60+ MPH) Use the following flow chart for diagnosis and correction: DYNAMIC CHECK Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of vibration/shake condition. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 6823 VISUAL INSPECTION (See illustration) TIRE/WHEEL/HUB RUNOUT CHECKS NOTE: ENSURE THE WHEEL BEARINGS ARE PROPERLY ADJUSTED BEFORE PROCEEDING. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 6824 Use a dial indicator to check the radial and lateral tire/wheel runouts on vehicle (refer to Figure 1). Mark the point of maximum radial and lateral runout on the tires/wheels. SPECIFICATIONS: Radial runout: 0.030 in. (0.762 mm) or LESS Lateral runout: 0.030 in. (0.762 mm) or LESS Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 6825 Mark the tire AND wheel at the point of highest runout. Remove the tire from the wheel and check the wheel runouts (check BOTH sides of the wheel at the bead seats (refer to Figure 2) with wheel mounted on an off car balancer. SPECIFICATIONS: Radial runout: 0.030 in. (0.762 mm) or LESS Lateral runout: 0.030 in. (0.762 mm) or LESS NOTE: HUB MEASUREMENTS APPLY TO FRONT HUBS ONLY ON FRONT WHEEL DRIVE (FWD) VEHICLES AND TO FRONT AND REAR HUBS ON ALL WHEEL DRIVE (AWD) VEHICLES. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 6826 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 220294 > Feb > 94 > Tires/Wheels - Smooth Road Vibration/Shake > Page 6827 Measure hub wheel pilot diameter (refer to Figure 4). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels Wheels: All Technical Service Bulletins Recall - Stamped Steel Road Wheels No. 603 January, 1994 To: All Dodge and Chrysler-Plymouth Dealers Subject: Safety Recall # 603 -- Stamped Steel Road Wheels Models: 1994 Model Year Dodge Grand Caravan, Plymouth Grand Voyager and Chrysler Town and Country Vehicles Built on September 23 and 24, 1993 and Equipped with 15" Stamped Steel Wheels and/or a 15" Full Size Stamped Steel Spare. The nut seat of the stamped steel road wheel may be misformed and result in the loss of lug nut torque retention. To correct the condition, all wheels must be inspected for an "M1" manufacturing plant code and all suspect wheels must be replaced. Less than 100 vehicles are involved in this recall. IMPORTANT: Some of the involved vehicles may be in dealer inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by Certified Mail. Important: Dealer notification by Certified Mail is required by federal law for all safety recalls. Responsible dealership personnel should be instructed to sign for this Certified Mail without hesitation as it concerns urgent safety recall information. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. All dealers: Each Dodge and Chrysler-Plymouth dealer will receive a copy of this dealer recall notification letter by Compak mail. DIAL System Function 70 All involved vehicles will be entered to DIAL System Function 70 at the time of recall implementation for dealer inquiry by VIN as needed. Parts Important: Due to the small number of involved vehicles and the unknown number of wheels required for each vehicle, no parts will be distributed initially to dealers. Dealers are requested to order parts only to support scheduled repairs. Wheel Packages, Recall PN C3905750, may be ordered at dealer cost to support customer demand. Owners were requested to inspect their vehicle to determine the number of replacement wheels required. Dealers should inquire if the owner performed the inspection and order the required parts when scheduling the service appointment. Each parts package contains the components (see illustration). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 6832 Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to inspect wheels for the suspect manufacturing plant code and/or schedule appointments for the service with their dealers at the earliest possible date. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure A. Inspect Wheel Manufacturing Plant Code: NOTE: Vehicle may have one, four or five wheels to be inspected. A1. FOR VEHICLES EQUIPPED WITH 15" STAMPED STEEL WHEELS (Sales Code WCF): a. Remove all wheel covers. b. Inspect wheel manufacturing plant code located above valve stem (Figure 1). NOTE: Manufacturing plant code may be covered by a green sticker. Remove and discard sticker as necessary. A2. FOR VEHICLES EQUIPPED WITH 15" FULL SIZE STAMPED STEEL SPARE (Sales Code -TBB): a. Gain access to spare. b. Inspect wheel manufacturing plant code located above valve stem (Figure 1). NOTE: Manufacturing plant code may be covered by a green sticker. Remove and discard sticker as necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 6833 A3. If any of the wheels inspected contain a Manufacturing Plant Code of M1, replace the affected wheel as instructed in Section B. If none of the wheels have the M1 plant code, reinstall wheel covers and/or secure spare, no further action is required. NOTE: Replace only those wheels having the M1 plant code. B. Replace Wheel: B1. Remove all wheels with suspect M1 plant code. Discard lug nuts. B2. Remove tire(s) from wheel(s). Set wheel(s) aside for return to Warranty Material Return Center. B3. Install supplied valve stem(s). B4. Mount and balance tire(s) on supplied wheel(s). B5. Install wheel and tire assembly on vehicle using supplied lug nuts. Tighten lug nuts to 95 ft.lbs. (130 N-m) torque. B6. Reinstall wheel cover(s) and/or secure spare. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances (see illustration). Add the cost of any recall parts packages used plus applicable dealer allowance to your claim. Parts Return Removed wheels must be returned to the Warranty Material Return Center. Note: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation 429-10-04 P.O. Box 1919 Detroit, Michigan 48231-1919 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 6834 SAFETY RECALL -- Stamped Steel Road Wheels Dear Chrysler Corporation Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1994 model Dodge Grand Caravan, Chrysler Town & Country and Plymouth Grand Voyager vehicles. The lug nuts attaching the stamped steel road wheels may loosen and result in a wheel becoming loose. This could result in an accident without prior warning. Your vehicle, identified on the enclosed form, is affected. For this reason we ask that you arrange for service to correct the condition without delay. The service and required parts as described in this letter will be provided free of charge. The stamped steel road wheel lug nut seats may have been misformed with an incorrect taper, which can result in loosening of the lug nuts. These wheels were used on vehicles equipped with 15" wheels with full wheel covers and also for 15" full size spare tires. You may inspect for suspect wheels yourself. Please refer to the instructions on the reverse side of this letter for details. If no suspect wheels are found, no further action is necessary. Please mark "INSPECTED -- OK" on the pre-addressed Vehicle Disposition Form portion of the enclosed owner notification form and put it in the mail. No postage is required. If you prefer not to do the inspection yourself, your dealer will do the inspection for you. To correct the condition, your dealer will inspect the manufacturing plant code of all steel wheels and replace any suspect wheels. The inspection will take less than one-half hour to complete. However, additional time may be required depending on how many wheels require replacement and how dealer appointments are scheduled and processed. To obtain this free service: ^ Contact your dealer as soon as possible to schedule an appointment for the service. If you performed the wheel inspection, be sure to inform your dealer of the number of suspect wheels found on your vehicle so the proper quantity of replacement wheels is ordered prior to your service appointment. ^ Take the enclosed Owner Notification Form with you at the time of your appointment and give it to your dealer. The form identifies the vehicle and the service that is required. If you have any problem obtaining the needed repair, please call the Chrysler Customer Center, toll free, at (800) 992-1997. A representative will assist you in getting your vehicle repaired. We regret any inconvenience which this action may cause you. However, we are concerned about your safety. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington D.C. area residents may call 366-0123.) Thank you for your attention to this important matter. STAMPED STEEL WHEEL INSPECTION INSTRUCTIONS 1994 DODGE GRAND CARAVAN, PLYMOUTH GRAND VOYAGER AND CHRYSLER TOWN & COUNTRY FOR VEHICLES EQUIPPED WITH 15" STAMPED STEEL WHEELS: ^ Remove all wheel covers. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 603 > Jan > 94 > Recall - Stamped Steel Road Wheels > Page 6835 ^ Inspect wheel manufacturing plant code located above valve stem as shown. ^ Reinstall wheel covers. FOR VEHICLES EQUIPPED WITH A 15" STAMPED STEEL WHEEL FULL SIZE SPARE: Gain access to spare following the instructions in your Owner's Manual. Inspect wheel manufacturing plant code located above valve stem as shown. If any of the wheels inspected contain a manufacturing plant code of M1, make an appointment with your dealer to have the suspect wheel(s) replaced. NOTE: Plant code may be covered by a green sticker. Remove and discard sticker as necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 210994 > Jun > 94 > M/T - Shifter Squeak When Shifting Shifter M/T: All Technical Service Bulletins M/T - Shifter Squeak When Shifting NO: 21-09-94 GROUP: Transmission EFFECTIVE DATE: Jun. 10 1994 SUBJECT: Shifter Squeak - Manual Transmission MODELS: 1990 - 1993 (AA) Spirit/Acclaim/LeBaron Sedan 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1994 (AS) Town & Country/Caravan/Voyager 1995 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION. DISCUSSION: A squeak noise may occur when shifting into or out of a gear. The noise is coming from where the select shift cable attaches to the gear shift lever. DO NOT ATTEMPT TO LUBRICATE THE SHIFTER PIN TO ELIMINATE THE SQUEAK NOISE. PETROLEUM BASE LUBRICANTS WILL REDUCE THE DURABILITY OF THE CABLE ISOLATOR. If a subject vehicle exhibits this condition, replace the shifter assembly using the procedure outlined in the appropriate service manual. The correct part numbers for the shifter assembly are listed below: 4670218 AP and AA Vehicles 4670219 AS Vehicles 4670220 PL Vehicles POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments Fig. 3 Wheel bearing assembly 1. Raise and support rear of vehicle. 2. Tighten adjusting nut to specifications, while rotating wheel. 3. Stop wheel and loosen adjusting nut by 1/4 turn. 4. Tighten adjusting nut finger tight. Endplay should be .001-.003 inch. 5. Install castle lock with slots aligned with cotter pin hole. 6. Install cotter pin and grease cap. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front This hub and bearing assembly is being used on certain extended wheelbase Caravan, Voyager and Mini Ram Vans. This unit is serviced as a complete assembly, and is attached to the steering knuckle by four mounting screws that are removed from the rear of the knuckle assembly. Remove 1. Remove cotter pin, nut lock, and spring washer. 2. Loosen hub nut while the vehicle is on the floor with the brakes applied. The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut. 3. Raise vehicle. 4. Remove hub nut, washer, and wheel and tire assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6851 5. Disconnect tie rod end from steering arm with Tool C-3894-A. 6. Remove clamp bolt securing ball joint stud into steering knuckle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6852 7. Remove caliper guide pins and separate caliper assembly from braking disc. SUPPORT CALIPER WITH WIRE HOOK AND NOT BY HYDRAULIC HOSE. Remove braking disc. 8. Separate ball joint stud from knuckle assembly. Pull knuckle assembly out and away from driveshaft. NOTE: Care must be taken not to separate the Inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint, driveshaft must be supported. 9. Remove the four hub and bearing assembly mounting screws from rear of steering knuckle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6853 10. Remove hub and bearing assembly. Replacement of the grease seal is recommended whenever this service is performed. Installation 1. Install new hub and bearing assembly and tighten screws in a criss-cross pattern to 45 ft.lbs. (65 Nm.). CAUTION: Knuckle and bearing mounting surfaces must be smooth and completely free of foreign material or nicks. 2. Position new seal in recess and assemble installer Tool C-4698 tool is provided with a handle and dual purpose drive head for installing seal into knuckle and (head reversed) for installing wear sleeve into C/V joint housing). 3. Assemble tool and install seal. CAUTION: During any service procedures where knuckle and driveshaft are separated, thoroughly clean seal and wear sleeve and relubricate BOTH components. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6854 4. Lubricate the full circumference of the seal (and wear sleeve) with MOPAR Multi-Purpose Lubricant or equivalent. 5. Install driveshaft through hub, then install steering knuckle assembly on lower control arm ball joint stud. 6. Install original (or equivalent) ball joint to knuckle clamp bolt, torque to 95 Nm (70 ft.lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6855 7. Install tie rod end into steering arm, tighten nut to 47 Nm (35 ft.lbs.) torque and install cotter key. 8. Install braking disc. 9. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment on knuckle assembly. Install guide pins and tighten to 25-35 Nm (18-26 ft.lbs.). When installing guide pins, use extreme caution not to cross the threads. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6856 10. Install washer and hub nut after cleaning foreign matter from threads. 11. With brakes applied, tighten nut to 180 ft.lbs. (244 Nm). 12. Install spring washer, nut lock, and new cotter pin. Wrap cotter pin prongs tightly around nut lock. 13. Install wheel and tire assembly. Tighten wheel nuts to 85 ft.lbs. (115 Nm). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6857 Wheel Bearing: Service and Repair Rear REMOVAL AND INSTALLATION 1. Remove the rear tire and wheel assembly. 2. Remove grease cap, cotter pin, nut lock, nut, thrust washer and outer wheel bearing. 3. Carefully slide hub or drum from spindle. Do not drag inner bearing or grease seal over stub axle (thread, bearing, and oil seal may be damaged.) Using an appropriate tool remove the grease seal and inner bearing from the drum or hub. Discard grease seal, a new seal should be used when reinstalling the inner bearing. 4. Thoroughly clean all old grease from the outer and inner bearings, bearing cups and hub cavity. To clean bearings, soak them in an appropriate cleaning solvent. Strike the flat surface of the bearing inner race against a hardwood block several times, to loosen grease. Immerse the bearings in solvent between blows to jar loose and wash old particles of hardened grease from bearings. Repeat this operation until bearings are clean. Bearings can be dried using compressed air but do not spin the bearings. After cleaning, oil the bearings with engine oil. Insert the bearing into its appropriate cup, apply pressure to the bearing while rotating it to test them for pitting and roughness. Replace all worn or defective bearings. If bearing shows signs of pitting or roughness they should be replaced. Bearings must be replaced as a set, both the cup and the bearing need to be replaced at the same time. If bearings are suitable for further use, remove engine oil from bearings using appropriate solvent and dry bearings. Repack the bearings using a Multi-Purpose NLGI. Grade 2 EP Grease such as Mopar® or equivalent, and place them in a clean covered container until ready for installation. If a bearing packer is not available, hand pack grease into all cavities between bearing cage and rollers. 5. If bearings and cups are to be replaced, remove cups from the drum or hub using a brass drift or suitable remover. 6. Replace bearing cups with appropriate installing tool. 7. Install inner bearing in grease coated hub and bearing cup, and install new grease seals using the appropriate seal installer. 8. Coat outer hub cavity and cup with grease. 9. Before installing hub or drum assembly, inspect stub axle and seal surface for burrs or roughness, and smooth out all rough surfaces. 10. Coat the stub axle with Multi-Purpose NLGI, Grade 2 EP grease or equivalent. 11. Carefully slide the hub of drum assembly onto the stub axle. Do not drag seal or inner bearing over the threaded area of the stub axle. 12. Install outer bearing, thrust washer and nut. 13. Tighten the wheel bearing adjusting nut to 27 to 34 Nm (240 to 300 in.lbs.) while rotating hub or drum assembly. This seats the bearings. 14. Back off adjusting nut 1/4 turn (90°) then tighten adjusting nut only finger tight. 15. Position the nut lock over the bearing adjusting nut with one pair of slots in line with the cotter pin hole in the stub axle. Install cotter pin. 16. Install the grease caps and the wheel and tire assemblies. Tighten wheel stud nuts to 115 Nm (85 ft. lbs.) on all models. Reinstall wheel covers if so equipped. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front Wheel Hub: Service and Repair Front This hub and bearing assembly is being used on certain extended wheelbase Caravan, Voyager and Mini Ram Vans. This unit is serviced as a complete assembly, and is attached to the steering knuckle by four mounting screws that are removed from the rear of the knuckle assembly. Remove 1. Remove cotter pin, nut lock, and spring washer. 2. Loosen hub nut while the vehicle is on the floor with the brakes applied. The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut. 3. Raise vehicle. 4. Remove hub nut, washer, and wheel and tire assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 6862 5. Disconnect tie rod end from steering arm with Tool C-3894-A. 6. Remove clamp bolt securing ball joint stud into steering knuckle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 6863 7. Remove caliper guide pins and separate caliper assembly from braking disc. SUPPORT CALIPER WITH WIRE HOOK AND NOT BY HYDRAULIC HOSE. Remove braking disc. 8. Separate ball joint stud from knuckle assembly. Pull knuckle assembly out and away from driveshaft. NOTE: Care must be taken not to separate the Inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint, driveshaft must be supported. 9. Remove the four hub and bearing assembly mounting screws from rear of steering knuckle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 6864 10. Remove hub and bearing assembly. Replacement of the grease seal is recommended whenever this service is performed. Installation 1. Install new hub and bearing assembly and tighten screws in a criss-cross pattern to 45 ft.lbs. (65 Nm.). CAUTION: Knuckle and bearing mounting surfaces must be smooth and completely free of foreign material or nicks. 2. Position new seal in recess and assemble installer Tool C-4698 tool is provided with a handle and dual purpose drive head for installing seal into knuckle and (head reversed) for installing wear sleeve into C/V joint housing). 3. Assemble tool and install seal. CAUTION: During any service procedures where knuckle and driveshaft are separated, thoroughly clean seal and wear sleeve and relubricate BOTH components. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 6865 4. Lubricate the full circumference of the seal (and wear sleeve) with MOPAR Multi-Purpose Lubricant or equivalent. 5. Install driveshaft through hub, then install steering knuckle assembly on lower control arm ball joint stud. 6. Install original (or equivalent) ball joint to knuckle clamp bolt, torque to 95 Nm (70 ft.lbs.). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 6866 7. Install tie rod end into steering arm, tighten nut to 47 Nm (35 ft.lbs.) torque and install cotter key. 8. Install braking disc. 9. Carefully lower caliper over braking disc and guide hold-down spring under machined abutment on knuckle assembly. Install guide pins and tighten to 25-35 Nm (18-26 ft.lbs.). When installing guide pins, use extreme caution not to cross the threads. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 6867 10. Install washer and hub nut after cleaning foreign matter from threads. 11. With brakes applied, tighten nut to 180 ft.lbs. (244 Nm). 12. Install spring washer, nut lock, and new cotter pin. Wrap cotter pin prongs tightly around nut lock. 13. Install wheel and tire assembly. Tighten wheel nuts to 85 ft.lbs. (115 Nm). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 6868 Wheel Hub: Service and Repair Rear REMOVAL AND INSTALLATION 1. Remove the rear tire and wheel assembly. 2. Remove grease cap, cotter pin, nut lock, nut, thrust washer and outer wheel bearing. 3. Carefully slide hub or drum from spindle. Do not drag inner bearing or grease seal over stub axle (thread, bearing, and oil seal may be damaged.) Using an appropriate tool remove the grease seal and inner bearing from the drum or hub. Discard grease seal, a new seal should be used when reinstalling the inner bearing. 4. Thoroughly clean all old grease from the outer and inner bearings, bearing cups and hub cavity. To clean bearings, soak them in an appropriate cleaning solvent. Strike the flat surface of the bearing inner race against a hardwood block several times, to loosen grease. Immerse the bearings in solvent between blows to jar loose and wash old particles of hardened grease from bearings. Repeat this operation until bearings are clean. Bearings can be dried using compressed air but do not spin the bearings. After cleaning, oil the bearings with engine oil. Insert the bearing into its appropriate cup, apply pressure to the bearing while rotating it to test them for pitting and roughness. Replace all worn or defective bearings. If bearing shows signs of pitting or roughness they should be replaced. Bearings must be replaced as a set, both the cup and the bearing need to be replaced at the same time. If bearings are suitable for further use, remove engine oil from bearings using appropriate solvent and dry bearings. Repack the bearings using a Multi-Purpose NLGI. Grade 2 EP Grease such as Mopar® or equivalent, and place them in a clean covered container until ready for installation. If a bearing packer is not available, hand pack grease into all cavities between bearing cage and rollers. 5. If bearings and cups are to be replaced, remove cups from the drum or hub using a brass drift or suitable remover. 6. Replace bearing cups with appropriate installing tool. 7. Install inner bearing in grease coated hub and bearing cup, and install new grease seals using the appropriate seal installer. 8. Coat outer hub cavity and cup with grease. 9. Before installing hub or drum assembly, inspect stub axle and seal surface for burrs or roughness, and smooth out all rough surfaces. 10. Coat the stub axle with Multi-Purpose NLGI, Grade 2 EP grease or equivalent. 11. Carefully slide the hub of drum assembly onto the stub axle. Do not drag seal or inner bearing over the threaded area of the stub axle. 12. Install outer bearing, thrust washer and nut. 13. Tighten the wheel bearing adjusting nut to 27 to 34 Nm (240 to 300 in.lbs.) while rotating hub or drum assembly. This seats the bearings. 14. Back off adjusting nut 1/4 turn (90°) then tighten adjusting nut only finger tight. 15. Position the nut lock over the bearing adjusting nut with one pair of slots in line with the cotter pin hole in the stub axle. Install cotter pin. 16. Install the grease caps and the wheel and tire assemblies. Tighten wheel stud nuts to 115 Nm (85 ft. lbs.) on all models. Reinstall wheel covers if so equipped. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls: > NHTSA93V215000 > Dec > 93 > Recall 93V215000: Defective Wheel Lug Nut Seats Wheel Fastener: Recalls Recall 93V215000: Defective Wheel Lug Nut Seats WHEELS WITH MISFORMED LUG NUT SEATS WERE INSTALLED ON THESE VEHICLES. THIS CAUSES REDUCED NUT TO WHEEL CONTACT AREA AND LIMITS THE WHEEL SELF-CENTERING CAPABILITY DURING INSTALLATION. THIS RESULTS IN LOSS OF WHEEL LUG NUT TORQUE RETENTION. LOSS OF LUG NUT TORQUE RETENTION MAY LEAD TO WHEEL LUG FAILURE WHICH MAY CAUSE WHEEL SEPARATION AND AN ACCIDENT. INSPECT THE WHEEL ASSEMBLY PLANT CODE; REPLACE WHEELS KNOWN TO HAVE THE PROBLEM AND INSTALL NEW LUG NUTS. SYSTEM: WHEELS; LUGS; NUTS. VEHICLE DESCRIPTION: VANS WITH 15" STAMPED STEEL ROAD WHEELS OR 15" STAMPED STEEL SPARE WHEEL. NOTE: IF YOU HAVE ANY PROBLEMS OBTAINING THE NEEDED REPAIR, PLEASE CONTACT THE CHRYSLER ZONE SERVICE OFFICE IN YOUR AREA. IT IS LISTED UNDER"SERVICE ASSISTANCE" IN YOUR OWNER'S MANUAL. A ZONE REPRESENTATIVE WILL ARRANGE FOR PROMPT ATTENTION TO YOUR VEHICLE. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTATRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. 1994 CHRYSLER TRUCK TOWN AND COUNTRY 1994 DODGE TRUCK GRAND CARAVAN 1994 PLYMOUTH TRUCK GRAND VOYAGER Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > NHTSA93V215000 > Dec > 93 > Recall 93V215000: Defective Wheel Lug Nut Seats Wheel Fastener: All Technical Service Bulletins Recall 93V215000: Defective Wheel Lug Nut Seats WHEELS WITH MISFORMED LUG NUT SEATS WERE INSTALLED ON THESE VEHICLES. THIS CAUSES REDUCED NUT TO WHEEL CONTACT AREA AND LIMITS THE WHEEL SELF-CENTERING CAPABILITY DURING INSTALLATION. THIS RESULTS IN LOSS OF WHEEL LUG NUT TORQUE RETENTION. LOSS OF LUG NUT TORQUE RETENTION MAY LEAD TO WHEEL LUG FAILURE WHICH MAY CAUSE WHEEL SEPARATION AND AN ACCIDENT. INSPECT THE WHEEL ASSEMBLY PLANT CODE; REPLACE WHEELS KNOWN TO HAVE THE PROBLEM AND INSTALL NEW LUG NUTS. SYSTEM: WHEELS; LUGS; NUTS. VEHICLE DESCRIPTION: VANS WITH 15" STAMPED STEEL ROAD WHEELS OR 15" STAMPED STEEL SPARE WHEEL. NOTE: IF YOU HAVE ANY PROBLEMS OBTAINING THE NEEDED REPAIR, PLEASE CONTACT THE CHRYSLER ZONE SERVICE OFFICE IN YOUR AREA. IT IS LISTED UNDER"SERVICE ASSISTANCE" IN YOUR OWNER'S MANUAL. A ZONE REPRESENTATIVE WILL ARRANGE FOR PROMPT ATTENTION TO YOUR VEHICLE. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTATRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. 1994 CHRYSLER TRUCK TOWN AND COUNTRY 1994 DODGE TRUCK GRAND CARAVAN 1994 PLYMOUTH TRUCK GRAND VOYAGER Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 180594 > Apr > 94 > TCC - Acceleration Shudder/DTC 38 Set Torque Converter: All Technical Service Bulletins TCC - Acceleration Shudder/DTC 38 Set NO: 18-05-94 GROUP: Vehicle Performance DATE: Apr. 8, 1994 SUBJECT: Vehicle Shudder During Torque Convertor EMCC Operation MODELS: 1993 - 1994 (AA) Acclaim/Spirit/LeBaron Sedan 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1993 (AG) Daytona 1993 - 1994 (AJ) LeBaron Coupe/LeBaron Convertible 1993 - 1994 (AP) Sundance/Shadow 1993 - 1994 (AS) Caravan/Voyager/Town & Country 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built After MDH 02-08-92) 1993 - 1994 (LH) Concorde/Intrepid/Vision 1994 (LH) LHS/New Yorker NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 41TE OR 42LE AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Light to moderate acceleration shudder during torque converter EMCC (Electronic Modulated Converter Clutch) operation. Most noticeable on smooth roads, or on long, moderate uphill grades (depending on final drive ratio, approximately 28 to 42 MPH). This shudder condition is generally the result of leakage in the transmission front pump caused by a worn pump bushing. It is sometimes accompanied by pump whine and Diagnostic Trouble Code 38 (Torque Converter Control Out of Range). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II or III) with appropriate diagnostic procedure manual, verify that all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference, and repair as necessary. If Diagnostic Trouble Code 38 is present, proceed to the repair procedure. If no codes are present and all systems are functioning correctly, proceed with the following: A. Inspect the engine mounts for signs of deterioration or grounding. Repair or replace as necessary. B. Inspect all rotating components such as halfshafts, brake rotors, tires and wheels for any abnormal conditions that could contribute to low frequency vibrations. C. Road test the vehicle at normal operating temperatures while monitoring transmission performance using a DRB II or III. Use the RPM display screen, in the transmission diagnostic section, to display converter clutch function and throttle angle. EMCC shudder generally is encountered at 10 to 15 degrees throttle on smooth roads between 38 to 42 MPH depending on final drive ratio. The PRNDL readout on the DRB II or III can be either "3PL" or "4PL" during the shudder. To verify that the shudder is EMCC induced, the EMCC feature should be disengaged. This can be done by accelerating at medium/heavy throttle, or lightly depressing the brake pedal, or disengaging the throttle. If after doing any of these and the shudder disappears, go to the repair procedure. PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 180594 > Apr > 94 > TCC - Acceleration Shudder/DTC 38 Set > Page 6887 REPAIR PROCEDURE: This bulletin involves replacing the transmission front pump assembly and the transmission torque converter with one that has bonded converter clutch friction material. 1. Following the procedures outlined in the appropriate Service Manual, replace the torque converter and the transmission front pump assembly with the parts identified in the parts section of this bulletin. 2. Perform the transmission oil cooler and lines reverse flushing and flow check procedure as outlined in the appropriate Service Manual. 3. Before performing the torque converter clutch break in reset procedure verify that the repair has corrected the shudder condition. Drive the vehicle under the same conditions that caused the shudder. If the condition is corrected, go to step four. NOTE: SOME LIGHT SHUDDER MAY BE PRESENT BEFORE RESETTING THE EMCC BREAK-IN PROCEDURE. If severe shudder is still present, refer to the diagnostic section of this bulletin and re-evaluate the items listed. 4. Using the DRB II or III Scan Tool, perform the Torque Converter Clutch Break-in Procedure listed in the appropriate Service Manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-60-05-91 1993 - 1994 AA, AC, AG, AP, AS & 1992 - 1993 AY 6.1 Hrs. 1993 - 1994 LH 7.1 Hrs. 21-00-05-63 1993 - 1994 AS (Anti-Lock Brake System Equipped) 0.2 Hrs. 21-00-05-64 1993 - 1994 AS (All Wheel Drive Equipped) 1.2 Hrs. FAILURE CODE: 52 - Improperly Machined Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 180594 > Apr > 94 > TCC - Acceleration Shudder/DTC 38 Set > Page 6893 REPAIR PROCEDURE: This bulletin involves replacing the transmission front pump assembly and the transmission torque converter with one that has bonded converter clutch friction material. 1. Following the procedures outlined in the appropriate Service Manual, replace the torque converter and the transmission front pump assembly with the parts identified in the parts section of this bulletin. 2. Perform the transmission oil cooler and lines reverse flushing and flow check procedure as outlined in the appropriate Service Manual. 3. Before performing the torque converter clutch break in reset procedure verify that the repair has corrected the shudder condition. Drive the vehicle under the same conditions that caused the shudder. If the condition is corrected, go to step four. NOTE: SOME LIGHT SHUDDER MAY BE PRESENT BEFORE RESETTING THE EMCC BREAK-IN PROCEDURE. If severe shudder is still present, refer to the diagnostic section of this bulletin and re-evaluate the items listed. 4. Using the DRB II or III Scan Tool, perform the Torque Converter Clutch Break-in Procedure listed in the appropriate Service Manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-60-05-91 1993 - 1994 AA, AC, AG, AP, AS & 1992 - 1993 AY 6.1 Hrs. 1993 - 1994 LH 7.1 Hrs. 21-00-05-63 1993 - 1994 AS (Anti-Lock Brake System Equipped) 0.2 Hrs. 21-00-05-64 1993 - 1994 AS (All Wheel Drive Equipped) 1.2 Hrs. FAILURE CODE: 52 - Improperly Machined Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 6894 Wheel Fastener: Specifications Fig 6 Wheel Stud Tightening Sequence When tightening wheel stud nuts, a criss-cross tightening sequence as shown should be followed. Tighten all stud nuts to one-half specified torque. Repeat, fully tightening to specified torque. Wheel stud lug nut torque 129 Nm (95 ft lb) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Locations Air Conditioning Switch: Locations Heater A/C Controls Center Of I/P Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Cable: > 240394 > Jan > 94 > Heater - Poor Performance Air Door Cable: Customer Interest Heater - Poor Performance NO: 24-03-94 GROUP: Heating and A/C DATE: Jan. 28, 1994 SUBJECT: Poor Heater Performance MODELS: 1992-1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Customer complains of poor heater performance which may be the result of a misadjusted clip on the blend air door cable. The vehicle will exhibit low air temperature in the full heat position. DIAGNOSIS: Move the temperature control lever all the way to the right to the full heat position. If the temperature control lever does not spring back or springs back less than .080 in. (2 mm) perform the following repair procedure. REPAIR PROCEDURE: This bulletin involves the adjustment of the clip on the blend air door cable. 1. Carefully remove the instrument panel center bezel that covers the A/C control assembly. Start by opening the ash tray and pulling at one of the bottom corners of the bezel. The bezel is held in place by a clip at each corner. 2. Remove the A/C control attaching screws and pull the A/C control assembly out about 3 in. (7.5 mm) of the instrument panel so the cable attaching point of the temperature control lever at the rear of the A/C control assembly is visible. 3. Lift the blend air door cable eyelet off the upstanding tang of the temperature control lever. 4. Push the eyelet of the cable toward the right until it stops. This moves the blend air door cable to the full cool position. 5. Now push on the eyelet of the cable with a firm and even pressure until the cable moves 1/8 to 1/4 in. (3 to 6 mm) farther to the right. 6. Re-install the blend air door cable eyelet over the upstanding tang of the temperature control lever. 7. Move the temperature control lever to the full heat position. If the control lever has at least .080 in. (2 mm) of spring back from the end of the slot, the clip has been successfully repositioned. If the lever still has less than .080 in. (2 mm) of spring back, repeat steps 3 through 7 until spring back is .080 in. or more. 8. Re-install the A/C control into the instrument panel and torque the attaching screws to 17 in.lbs. (1.9 N-m). 9. Move the temperature control lever to the full cool position and then back to the full heat position. The lever should spring back a minimum of .080 in. (2 mm) from the end of the slot. If the lever springs back in excess of 1/4 in. (6 mm) the temperature control lever should be forcefully pushed to the full heat position to properly position the clip. 10. Re-install the center bezel being sure that all 4 clips are properly engaged. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 24-50-25-91 0.2 Hrs. FAILURE CODE: 50 - Improper Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Cable: > 240394 > Jan > 94 > Heater - Poor Performance Air Door Cable: All Technical Service Bulletins Heater - Poor Performance NO: 24-03-94 GROUP: Heating and A/C DATE: Jan. 28, 1994 SUBJECT: Poor Heater Performance MODELS: 1992-1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Customer complains of poor heater performance which may be the result of a misadjusted clip on the blend air door cable. The vehicle will exhibit low air temperature in the full heat position. DIAGNOSIS: Move the temperature control lever all the way to the right to the full heat position. If the temperature control lever does not spring back or springs back less than .080 in. (2 mm) perform the following repair procedure. REPAIR PROCEDURE: This bulletin involves the adjustment of the clip on the blend air door cable. 1. Carefully remove the instrument panel center bezel that covers the A/C control assembly. Start by opening the ash tray and pulling at one of the bottom corners of the bezel. The bezel is held in place by a clip at each corner. 2. Remove the A/C control attaching screws and pull the A/C control assembly out about 3 in. (7.5 mm) of the instrument panel so the cable attaching point of the temperature control lever at the rear of the A/C control assembly is visible. 3. Lift the blend air door cable eyelet off the upstanding tang of the temperature control lever. 4. Push the eyelet of the cable toward the right until it stops. This moves the blend air door cable to the full cool position. 5. Now push on the eyelet of the cable with a firm and even pressure until the cable moves 1/8 to 1/4 in. (3 to 6 mm) farther to the right. 6. Re-install the blend air door cable eyelet over the upstanding tang of the temperature control lever. 7. Move the temperature control lever to the full heat position. If the control lever has at least .080 in. (2 mm) of spring back from the end of the slot, the clip has been successfully repositioned. If the lever still has less than .080 in. (2 mm) of spring back, repeat steps 3 through 7 until spring back is .080 in. or more. 8. Re-install the A/C control into the instrument panel and torque the attaching screws to 17 in.lbs. (1.9 N-m). 9. Move the temperature control lever to the full cool position and then back to the full heat position. The lever should spring back a minimum of .080 in. (2 mm) from the end of the slot. If the lever springs back in excess of 1/4 in. (6 mm) the temperature control lever should be forcefully pushed to the full heat position to properly position the clip. 10. Re-install the center bezel being sure that all 4 clips are properly engaged. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 24-50-25-91 0.2 Hrs. FAILURE CODE: 50 - Improper Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Technical Service Bulletins > Page 6913 Air Door Cable: Adjustments Temperature Control Cable Position and hold the TEMP lever all the way to the left side of the control panel. Slide the self adjusting clip toward the end of the cable, until the blend air door reaches its fully counter-clockwise position. Move the cable from full left to full right several times checking for smooth operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Technical Service Bulletins > Page 6914 Air Door Cable: Service and Repair REMOVAL AND INSTALLATION Temperature Control Cable 1. Disconnect battery negative cable. 2. Remove left silencer (kick pad) panel. 3. Remove parking brake release handle linkage. 4. Remove lower steering column cover. 5. Remove upper column cover. 6. Remove upper instrument panel pad. 7. Remove instrument panel upper fence screws. 8. Remove center instrument panel bezel. 9. Remove heater control unit. 10. Remove vacuum lines at heater control unit. 11. Remove console/module cover. 12. Remove right silencer (kick pad) panel. 13. Remove left lower reinforcement. 14. Remove lower steering column shroud. 15. Remove upper column shroud. 16. Disconnect column wiring. 17. Disconnect shift indicator. 18. Lower steering column. 19. Remove floor braces. 20. Remove right sill plate. 21. Remove left sill plate. 22. Remove A-pillar intermediate molding. 23. Remove hood release handle. 24. Remove steering column support nuts. 25. Loosen bolts holding instrument panel to cowl side panels. 26. Roll instrument panel down. 27. Remove temperature control cable. To install, reverse the preceding operation. To adjust temperature cable: Position the TEMP lever on the control to the cool side of its travel. Allowing the self-adjusting clip to slide on the cable, rotate the blend-air door crank counterclockwise by hand until it stops. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > Customer Interest for Air Duct: > 240594A > Dec > 94 > Low Heater Performance - Diagnosis/Repair Air Duct: Customer Interest Low Heater Performance - Diagnosis/Repair NO: 24-05-94 Rev. A GROUP: Heater & A/C DATE: Dec. 23, 1994 SUBJECT: Low Heater Performance Diagnosis/Repair THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-05-94, DATED MAR. 11, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ADD 1995 AND ES VEHICLES, AND ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1991 - **1995** (AS) Town & Country/Caravan/Voyager **1992 - 1995 (ES) Chrysler Voyager** SYMPTOM/CONDITION: Poor heater system performance at low ambient temperatures consisting of one or more of the following symptoms: A) Heater discharge duct temperature drops off at engine idle speed. B) Poor heater system performance resulting in cooler than expected average cabin temperature. C) Driver's side floor cold due to lack of direct heater air flow (1993 or 1994 models). Low heater performance may be caused by many factors within the heater and A/C system, the engine cooling system and/or the engine electronic management system. Proper diagnosis is essential to avoid additional customer inconvenience and needless component changes. It is very important for the Service Advisor/Technician to FIRST determine the specific customer complaint, and then match it to the three descriptions listed above. DIAGNOSIS/REPAIR PROCEDURE: If the customer complaint is SYMPTOM A or SYMPTOM B, perform the heater output test first. If the customer complaint is SYMPTOM C, go directly to the SYMPTOM C repair procedure. HEATER OUTPUT TEST With the engine idling at normal operating temperature, set the temperature control lever to the maximum heat position, the mode button to the floor position, and the blower switch to high. Using a thermometer, check the air temperature coming from the center floor outlets (Refer to the Temperature Reference Chart). If the vehicle meets the minimum floor outlet temperature specification, the vehicle is performing as designed and no further action should be taken. If the vehicle does not meet the minimum floor outlet temperature specification, continue to the appropriate Diagnosis/Repair Procedure. SYMPTOM A - Heater discharge duct temperature drops off at idle engine speeds. NOTE: A DROP IN OUTLET AIR TEMPERATURE AT IDLE IS NORMAL. THE FOLLOWING STEPS ARE TO ENSURE THE OUTLET TEMPERATURE IS AS HIGH AS POSSIBLE. 1. Verify with the Mopar Diagnostic System (MDS) Scan Tool (DRB II/III) that the engine idle is within specification. Specifications for vehicles with 1000 miles or more: 2.5L 800 - 1200 RPM 3.0L 610 - 900 RPM 3.3L 575 - 875 RPM 3.8L 575 - 875 RPM 2. Verify engine coolant temperature. A) Does engine temperature gauge read low? Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > Customer Interest for Air Duct: > 240594A > Dec > 94 > Low Heater Performance - Diagnosis/Repair > Page 6923 B) Verify coolant level and absence of air. Low coolant or trapped air will result in erratic heating characteristics. Add 50/50 coolant/water mix if needed. C) Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine systems are functioning as designed. If Diagnostic Trouble Code (DTC) 17 (engine is cold too long) is present, replace the engine coolant thermostat. If other DTC's are present, record them on the repair order for future reference and repair as necessary. SYMPTOM B - Poor heater system performance resulting in cooler than expected average cabin temperature. 1. Move the temperature control lever all the way to the right to the full heat position. If the temperature control lever does not spring back or springs back less than .080 in. (2 mm) perform the following repair procedure. A) Carefully remove the instrument panel center bezel that covers the A/C control assembly. Start by opening the ash tray on 1994 models or the glove box door on 1991-1993 models and pulling at one of the corners of the bezel. The bezel is held in place by a clip at each corner. B) Remove the A/C control attaching screws and pull the A/C control assembly out about 3 in. (7.5 mm) of the instrument panel so the cable attaching point of the temperature control lever at the rear of the A/C control assembly is visible. C) Lift the blend air door cable eyelet off the upstanding tang of the temperature control lever. NOTE: ON 1991-1993 VEHICLES, IT IS NOT NECESSARY TO DISCONNECT THE BLEND AIR CABLE FROM THE TEMPERATURE CONTROL LEVER. D) Push the eyelet of the cable toward the right until it stops. This moves the blend air door cable to the full cool position. E) Now push on the eyelet of the cable with a firm and even pressure until the cable moves 1/8 to 1/4 in. (3 to 6 mm) farther to the right. F) Re-install the blend air door cable eyelet over the upstanding tang of the temperature control lever. G) Move the temperature control lever to the full heat position. If the control lever has at least .080 in. (2 mm) of spring back from the end of the slot, the clip has been successfully repositioned. If the lever still has less than .080 in. (2 mm) of spring back, repeat steps "c" through "g" until spring back is .080 in. or more. H) Re-install the A/C control into the instrument panel and torque the attaching screws to 17 in.lbs. (1.9 N-m). I) Move the temperature control lever to the full cool position and then back to the full heat position. The lever should spring back a minimum of .080 in. (2 mm) from the end of the slot. If the lever springs back in excess of 1/4 in. (6 mm) the temperature control lever should be forcefully pushed to the full heat position to properly position the clip. J) Re-install the center bezel being sure that all 4 clips are properly engaged. 2. Verify engine coolant temperature. A) Does engine temperature gauge read low? B) Verify coolant level and absence of air. Low coolant or trapped air will result in erratic heating characteristics. Add 50/50 coolant/water mix if needed. C) Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III) verify that all engine systems are functioning as designed. If Diagnostic Trouble Code (DTC) 17 (engine is cold too long) is present, replace the engine coolant thermostat. If other DTC's are present, record them on the repair order for future reference, and repair as necessary. 3. CAUTION: Check for hot heater hoses into and out of BOTH the water valve and heater core. Should either component exhibit a cool temperature at the outlet, that component may be blocked or restricted. If a heater core is suspect, it should be replaced with an approved MOPAR replacement ONLY! SYMPTOM C - Drivers side floor cold, due to lack of direct heater air flow. PARTS REQUIRED: 1 3849219 Duct, Heat Distribution (for use on 1993 model vehicles only) 1993 Model Vehicle Repair Procedure: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > Customer Interest for Air Duct: > 240594A > Dec > 94 > Low Heater Performance - Diagnosis/Repair > Page 6924 If the vehicle is not equipped with a lower console, skip to step "i". A) Remove the center instrument panel bezel by carefully unsnapping it. B) Remove the two 5/16 in. hex head screws just above the cubby hole. C) Remove the ash receiver/cupholder assembly by depressing the two latching tabs. D) Remove the two 5/16 in. hex head screws at the rear of the ash receiver/cupholder assembly cavity. E) Remove the two 5/16 in. hex head screws at the lower right and left sides of the console. F) Pull the console loose and remove the three Phillips head screws holding the cubby hole to the console assembly. Two are in the front, one is on the rear. G) Remove the ash tray light. H) Remove the console. I) Remove the three 5/16 in. hex head screws holding the floor air distribution duct to the bottom of the heater/air conditioning housing. Remove the duct and discard it. J) Install revised duct (P/N 3849219) by reversing the steps above. 1994 Model Vehicle Repair Procedure: A) If so equipped, remove the two screws at the top and the two screws at the bottom of the premium console. Remove the console. B) Remove the three screws attaching the center floor air duct to the main floor air distribution duct. Remove the center floor air duct. C) Disconnect the two 25-way connectors from the body control module. D) Remove the three screws attaching the main floor duct to the climate control unit. Remove the main floor air duct. E) Modify the main floor air duct by cutting and taping as shown in the illustration. F) Reinstall by reversing steps "a" through "d". POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: SYMPTOM A Refer to the appropriate Labor Operation Time Schedule Manual for already existing Labor Operation No. as necessary. SYMPTOM B Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > Customer Interest for Air Duct: > 240594A > Dec > 94 > Low Heater Performance - Diagnosis/Repair > Page 6925 Labor Operation No. 24-50-25-91 0.2 Hrs. SYMPTOM C Labor Operation No. 24-65-49-90 1993 model vehicles 0.3 Hrs. 1994 model vehicles 0.5 Hrs. FAILURE CODE: SYMPTOM A Refer to the appropriate Labor Operation Time Schedules Manual for already existing Failure Code as necessary. SYMPTOM B 50 - Improper Adjustment SYMPTOM C 1993 model vehicles P8 - New Part 1994 model vehicles XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > Customer Interest for Air Duct: > 242193 > Sep > 93 > AC Ducts - Emit Odors Air Duct: Customer Interest AC Ducts - Emit Odors NO.: 24-21-93 GROUP: Air Conditioning DATE: Sep. 3, 1993 SUBJECT: Air Conditioning Ducts Emits Odor NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-12-92. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** MODELS: 1992**- 1993** (AC) Dynasty/New Yorker Salon (built after Jan. 31, 1992 - MDH 0131XX) 1992**- 1994** (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1992**- 1993** (AY) Imperial/New Yorker Fifth Avenue (built after Jan. 31, 1992 - MDH 0131XX) SYMPTOM/CONDITION: Some vehicles may emit an odor from the air conditioning ducts. The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related odors are possible, and are covered separately below: CAUSE AND CORRECTION - VEHICLES WITH LESS THAN 12,000 MILES **On some vehicles with the plate fin A/C evaporator, the manufacturing process occasionally results in an excessive amount of corrosion protection coating being applied on the evaporator external surfaces.** A heavy coating can result in an odor from the evaporator fins, especially when dry fins become wet from condensation. To correct this condition, the evaporator coil in the A/C unit must be replaced. Refer to the appropriate service manual for the replacement procedure. CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended use resulting from possible accumulation of foreign matter in the A/C unit. This condition is more likely to occur in vehicles that have been in extended use in humid climates. To correct this condition, the internal surfaces of the A/C air handling system will have to be cleaned by the repair procedure outlined in this bulletin. PARTS AND EQUIPMENT REQUIRED: VEHICLES WITH LESS THAN 12,000 MILES 1 Coil, A/C Evaporator AS 1992 4723069 AS 1993 - 1994 4474842 AC & AY 4677011 VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1 A/C Evaporator Cleaner 4728942 1 Reusable Applicator 4740319 1 Pair Of Rubber Gloves 1 Pair Of Safety Glasses REPAIR PROCEDURE: This bulletin involves cleaning and disinfecting the A/C evaporator and housing. NOTE: FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR CLEANER. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > Customer Interest for Air Duct: > 242193 > Sep > 93 > AC Ducts - Emit Odors > Page 6930 - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE WATER TO FLUSH EYES IF NECESSARY 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Correct if necessary. 2. Protect the interior of the vehicle with a drop cloth. 3. Start the engine, set the blower on HIGH, air on recirculate, turn the A/C compressor OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the evaporator coil. 4. Switch to outside air. With a shop rag, block about 90% of the outside air inlet to increase air velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the dash panel). Open the vehicles doors. On "AS" Body models, remove the resistor block. **NOTE: THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING THE SCREWS COUNTER-CLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT.** 5. Shake the bottle of evaporator cleaner. Connect the bottle and a compressed air supply, with at least 80 PSI of pressure, to the reusable applicator. 6. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty. Spray into the resistor block opening on "AS" models. 7. Turn the vehicle OFF and allow to soak for at least 30 minutes. 8. Wipe off any excess cleaner from around the instrument panel ducts. 9. Start the engine, set the blower on HIGH, air on recirculate, **turn the A/C compressor OFF, open all of the instrument panel ducts, and open all of the vehicles windows.** Run the vehicle for 20 minutes to dry the system. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. Replace Evaporator AC & AY 1992 - 1993 24-65-90-91 2.0 Hrs. AS 1992 - 1994 24-65-90-91 2.4 Hrs. Clean Evaporator AC, AS & AY 24-65-90-90 0.3 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Duct: > 240594A > Dec > 94 > Low Heater Performance - Diagnosis/Repair Air Duct: All Technical Service Bulletins Low Heater Performance - Diagnosis/Repair NO: 24-05-94 Rev. A GROUP: Heater & A/C DATE: Dec. 23, 1994 SUBJECT: Low Heater Performance Diagnosis/Repair THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-05-94, DATED MAR. 11, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS ADD 1995 AND ES VEHICLES, AND ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1991 - **1995** (AS) Town & Country/Caravan/Voyager **1992 - 1995 (ES) Chrysler Voyager** SYMPTOM/CONDITION: Poor heater system performance at low ambient temperatures consisting of one or more of the following symptoms: A) Heater discharge duct temperature drops off at engine idle speed. B) Poor heater system performance resulting in cooler than expected average cabin temperature. C) Driver's side floor cold due to lack of direct heater air flow (1993 or 1994 models). Low heater performance may be caused by many factors within the heater and A/C system, the engine cooling system and/or the engine electronic management system. Proper diagnosis is essential to avoid additional customer inconvenience and needless component changes. It is very important for the Service Advisor/Technician to FIRST determine the specific customer complaint, and then match it to the three descriptions listed above. DIAGNOSIS/REPAIR PROCEDURE: If the customer complaint is SYMPTOM A or SYMPTOM B, perform the heater output test first. If the customer complaint is SYMPTOM C, go directly to the SYMPTOM C repair procedure. HEATER OUTPUT TEST With the engine idling at normal operating temperature, set the temperature control lever to the maximum heat position, the mode button to the floor position, and the blower switch to high. Using a thermometer, check the air temperature coming from the center floor outlets (Refer to the Temperature Reference Chart). If the vehicle meets the minimum floor outlet temperature specification, the vehicle is performing as designed and no further action should be taken. If the vehicle does not meet the minimum floor outlet temperature specification, continue to the appropriate Diagnosis/Repair Procedure. SYMPTOM A - Heater discharge duct temperature drops off at idle engine speeds. NOTE: A DROP IN OUTLET AIR TEMPERATURE AT IDLE IS NORMAL. THE FOLLOWING STEPS ARE TO ENSURE THE OUTLET TEMPERATURE IS AS HIGH AS POSSIBLE. 1. Verify with the Mopar Diagnostic System (MDS) Scan Tool (DRB II/III) that the engine idle is within specification. Specifications for vehicles with 1000 miles or more: 2.5L 800 - 1200 RPM 3.0L 610 - 900 RPM 3.3L 575 - 875 RPM 3.8L 575 - 875 RPM 2. Verify engine coolant temperature. A) Does engine temperature gauge read low? Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Duct: > 240594A > Dec > 94 > Low Heater Performance - Diagnosis/Repair > Page 6936 B) Verify coolant level and absence of air. Low coolant or trapped air will result in erratic heating characteristics. Add 50/50 coolant/water mix if needed. C) Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine systems are functioning as designed. If Diagnostic Trouble Code (DTC) 17 (engine is cold too long) is present, replace the engine coolant thermostat. If other DTC's are present, record them on the repair order for future reference and repair as necessary. SYMPTOM B - Poor heater system performance resulting in cooler than expected average cabin temperature. 1. Move the temperature control lever all the way to the right to the full heat position. If the temperature control lever does not spring back or springs back less than .080 in. (2 mm) perform the following repair procedure. A) Carefully remove the instrument panel center bezel that covers the A/C control assembly. Start by opening the ash tray on 1994 models or the glove box door on 1991-1993 models and pulling at one of the corners of the bezel. The bezel is held in place by a clip at each corner. B) Remove the A/C control attaching screws and pull the A/C control assembly out about 3 in. (7.5 mm) of the instrument panel so the cable attaching point of the temperature control lever at the rear of the A/C control assembly is visible. C) Lift the blend air door cable eyelet off the upstanding tang of the temperature control lever. NOTE: ON 1991-1993 VEHICLES, IT IS NOT NECESSARY TO DISCONNECT THE BLEND AIR CABLE FROM THE TEMPERATURE CONTROL LEVER. D) Push the eyelet of the cable toward the right until it stops. This moves the blend air door cable to the full cool position. E) Now push on the eyelet of the cable with a firm and even pressure until the cable moves 1/8 to 1/4 in. (3 to 6 mm) farther to the right. F) Re-install the blend air door cable eyelet over the upstanding tang of the temperature control lever. G) Move the temperature control lever to the full heat position. If the control lever has at least .080 in. (2 mm) of spring back from the end of the slot, the clip has been successfully repositioned. If the lever still has less than .080 in. (2 mm) of spring back, repeat steps "c" through "g" until spring back is .080 in. or more. H) Re-install the A/C control into the instrument panel and torque the attaching screws to 17 in.lbs. (1.9 N-m). I) Move the temperature control lever to the full cool position and then back to the full heat position. The lever should spring back a minimum of .080 in. (2 mm) from the end of the slot. If the lever springs back in excess of 1/4 in. (6 mm) the temperature control lever should be forcefully pushed to the full heat position to properly position the clip. J) Re-install the center bezel being sure that all 4 clips are properly engaged. 2. Verify engine coolant temperature. A) Does engine temperature gauge read low? B) Verify coolant level and absence of air. Low coolant or trapped air will result in erratic heating characteristics. Add 50/50 coolant/water mix if needed. C) Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III) verify that all engine systems are functioning as designed. If Diagnostic Trouble Code (DTC) 17 (engine is cold too long) is present, replace the engine coolant thermostat. If other DTC's are present, record them on the repair order for future reference, and repair as necessary. 3. CAUTION: Check for hot heater hoses into and out of BOTH the water valve and heater core. Should either component exhibit a cool temperature at the outlet, that component may be blocked or restricted. If a heater core is suspect, it should be replaced with an approved MOPAR replacement ONLY! SYMPTOM C - Drivers side floor cold, due to lack of direct heater air flow. PARTS REQUIRED: 1 3849219 Duct, Heat Distribution (for use on 1993 model vehicles only) 1993 Model Vehicle Repair Procedure: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Duct: > 240594A > Dec > 94 > Low Heater Performance - Diagnosis/Repair > Page 6937 If the vehicle is not equipped with a lower console, skip to step "i". A) Remove the center instrument panel bezel by carefully unsnapping it. B) Remove the two 5/16 in. hex head screws just above the cubby hole. C) Remove the ash receiver/cupholder assembly by depressing the two latching tabs. D) Remove the two 5/16 in. hex head screws at the rear of the ash receiver/cupholder assembly cavity. E) Remove the two 5/16 in. hex head screws at the lower right and left sides of the console. F) Pull the console loose and remove the three Phillips head screws holding the cubby hole to the console assembly. Two are in the front, one is on the rear. G) Remove the ash tray light. H) Remove the console. I) Remove the three 5/16 in. hex head screws holding the floor air distribution duct to the bottom of the heater/air conditioning housing. Remove the duct and discard it. J) Install revised duct (P/N 3849219) by reversing the steps above. 1994 Model Vehicle Repair Procedure: A) If so equipped, remove the two screws at the top and the two screws at the bottom of the premium console. Remove the console. B) Remove the three screws attaching the center floor air duct to the main floor air distribution duct. Remove the center floor air duct. C) Disconnect the two 25-way connectors from the body control module. D) Remove the three screws attaching the main floor duct to the climate control unit. Remove the main floor air duct. E) Modify the main floor air duct by cutting and taping as shown in the illustration. F) Reinstall by reversing steps "a" through "d". POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: SYMPTOM A Refer to the appropriate Labor Operation Time Schedule Manual for already existing Labor Operation No. as necessary. SYMPTOM B Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Duct: > 240594A > Dec > 94 > Low Heater Performance - Diagnosis/Repair > Page 6938 Labor Operation No. 24-50-25-91 0.2 Hrs. SYMPTOM C Labor Operation No. 24-65-49-90 1993 model vehicles 0.3 Hrs. 1994 model vehicles 0.5 Hrs. FAILURE CODE: SYMPTOM A Refer to the appropriate Labor Operation Time Schedules Manual for already existing Failure Code as necessary. SYMPTOM B 50 - Improper Adjustment SYMPTOM C 1993 model vehicles P8 - New Part 1994 model vehicles XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Duct: > 242193 > Sep > 93 > AC Ducts - Emit Odors Air Duct: All Technical Service Bulletins AC Ducts - Emit Odors NO.: 24-21-93 GROUP: Air Conditioning DATE: Sep. 3, 1993 SUBJECT: Air Conditioning Ducts Emits Odor NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-12-92. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** MODELS: 1992**- 1993** (AC) Dynasty/New Yorker Salon (built after Jan. 31, 1992 - MDH 0131XX) 1992**- 1994** (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1992**- 1993** (AY) Imperial/New Yorker Fifth Avenue (built after Jan. 31, 1992 - MDH 0131XX) SYMPTOM/CONDITION: Some vehicles may emit an odor from the air conditioning ducts. The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related odors are possible, and are covered separately below: CAUSE AND CORRECTION - VEHICLES WITH LESS THAN 12,000 MILES **On some vehicles with the plate fin A/C evaporator, the manufacturing process occasionally results in an excessive amount of corrosion protection coating being applied on the evaporator external surfaces.** A heavy coating can result in an odor from the evaporator fins, especially when dry fins become wet from condensation. To correct this condition, the evaporator coil in the A/C unit must be replaced. Refer to the appropriate service manual for the replacement procedure. CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended use resulting from possible accumulation of foreign matter in the A/C unit. This condition is more likely to occur in vehicles that have been in extended use in humid climates. To correct this condition, the internal surfaces of the A/C air handling system will have to be cleaned by the repair procedure outlined in this bulletin. PARTS AND EQUIPMENT REQUIRED: VEHICLES WITH LESS THAN 12,000 MILES 1 Coil, A/C Evaporator AS 1992 4723069 AS 1993 - 1994 4474842 AC & AY 4677011 VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1 A/C Evaporator Cleaner 4728942 1 Reusable Applicator 4740319 1 Pair Of Rubber Gloves 1 Pair Of Safety Glasses REPAIR PROCEDURE: This bulletin involves cleaning and disinfecting the A/C evaporator and housing. NOTE: FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR CLEANER. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Duct: > 242193 > Sep > 93 > AC Ducts - Emit Odors > Page 6943 - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE WATER TO FLUSH EYES IF NECESSARY 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Correct if necessary. 2. Protect the interior of the vehicle with a drop cloth. 3. Start the engine, set the blower on HIGH, air on recirculate, turn the A/C compressor OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the evaporator coil. 4. Switch to outside air. With a shop rag, block about 90% of the outside air inlet to increase air velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the dash panel). Open the vehicles doors. On "AS" Body models, remove the resistor block. **NOTE: THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING THE SCREWS COUNTER-CLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT.** 5. Shake the bottle of evaporator cleaner. Connect the bottle and a compressed air supply, with at least 80 PSI of pressure, to the reusable applicator. 6. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty. Spray into the resistor block opening on "AS" models. 7. Turn the vehicle OFF and allow to soak for at least 30 minutes. 8. Wipe off any excess cleaner from around the instrument panel ducts. 9. Start the engine, set the blower on HIGH, air on recirculate, **turn the A/C compressor OFF, open all of the instrument panel ducts, and open all of the vehicles windows.** Run the vehicle for 20 minutes to dry the system. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. Replace Evaporator AC & AY 1992 - 1993 24-65-90-91 2.0 Hrs. AS 1992 - 1994 24-65-90-91 2.4 Hrs. Clean Evaporator AC, AS & AY 24-65-90-90 0.3 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Front End Components Front Of Engine Compartment, Front Of Radiator Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and Inspection > Flow of Diagnosis Blower Motor Diagnosis (Noise/Vibration) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6952 Blower Motor Diagnosis (Electrical) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and Inspection > Page 6953 Blower Motor: Service and Repair 1. Remove lower right instrument panel. 2. Remove blower housing mounting screws. 3. Allow assembly to drop and remove from vehicle. 4. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description and Operation Blower Motor Relay: Description and Operation Chrysler does not use a Blower Motor Relay for these Year/Make/Model Vehicles. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Blower Motor Resistor RH Rear Corner Of Engine Compartment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Duct > Component Information > Technical Service Bulletins > Customer Interest for Cabin Ventilation Duct: > 235994 > Aug > 94 > Left B Post Exhauster - Loose Cabin Ventilation Duct: Customer Interest Left B Post Exhauster - Loose NO: 23-59-94 GROUP: Body DATE: Aug. 5, 1994 SUBJECT: Left "B"-Post Body Exhauster Retention MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager 1993 - 1994 (ES) Chrysler Voyager (European Market) SYMPTOM/CONDITION: The retention of the left "B"-post body exhauster on some vehicles may be inadequate. This may cause the "B"-post body exhauster to come out of the opening in the "B"-post on its own or with very little assistance. DIAGNOSIS: Inspect the left "B"-post for the presence or looseness of the "B"-post body exhauster. Perform the repair procedure if the exhauster is loose of missing. PARTS REQUIRED: AR 82300234 Sealant, RTV AR 4475320 Exhauster, Body REPAIR PROCEDURE: This bulletin involves adhering the "B"-post body exhauster to the "B"-post. 1. Remove the "B"-post body exhauster, or if necessary, obtain a new one, P/N 4475320. 2. Apply a 4 in. (100 mm) long 1/8 in. (3 mm) bead of RTV sealant, P/N 82300234, to both side flange surfaces of the "B"-post body exhauster that mate to the "B"-post (refer to illustration). 3. Install the "B"-post body exhauster into the opening in the "B"-post and press it into place. 4. Wipe the "B"-post body exhauster and the "B"-post clean of any excess RTV sealant that may have squeezed out from between the "B"-post body Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Duct > Component Information > Technical Service Bulletins > Customer Interest for Cabin Ventilation Duct: > 235994 > Aug > 94 > Left B Post Exhauster - Loose > Page 6968 exhauster and the "B"-post. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-02-89-91 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cabin Ventilation Duct: > 235994 > Aug > 94 > Left B Post Exhauster Loose Cabin Ventilation Duct: All Technical Service Bulletins Left B Post Exhauster - Loose NO: 23-59-94 GROUP: Body DATE: Aug. 5, 1994 SUBJECT: Left "B"-Post Body Exhauster Retention MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager 1993 - 1994 (ES) Chrysler Voyager (European Market) SYMPTOM/CONDITION: The retention of the left "B"-post body exhauster on some vehicles may be inadequate. This may cause the "B"-post body exhauster to come out of the opening in the "B"-post on its own or with very little assistance. DIAGNOSIS: Inspect the left "B"-post for the presence or looseness of the "B"-post body exhauster. Perform the repair procedure if the exhauster is loose of missing. PARTS REQUIRED: AR 82300234 Sealant, RTV AR 4475320 Exhauster, Body REPAIR PROCEDURE: This bulletin involves adhering the "B"-post body exhauster to the "B"-post. 1. Remove the "B"-post body exhauster, or if necessary, obtain a new one, P/N 4475320. 2. Apply a 4 in. (100 mm) long 1/8 in. (3 mm) bead of RTV sealant, P/N 82300234, to both side flange surfaces of the "B"-post body exhauster that mate to the "B"-post (refer to illustration). 3. Install the "B"-post body exhauster into the opening in the "B"-post and press it into place. 4. Wipe the "B"-post body exhauster and the "B"-post clean of any excess RTV sealant that may have squeezed out from between the "B"-post body Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cabin Ventilation Duct: > 235994 > Aug > 94 > Left B Post Exhauster Loose > Page 6974 exhauster and the "B"-post. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-02-89-91 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch: > 242593 > Dec > 93 > A/C Compressor - Moaning Noise Compressor Clutch: Customer Interest A/C Compressor - Moaning Noise NO.: 24-25-93 GROUP: Air Conditioning EFFECTIVE DATE: Dec. 31, 1993 SUBJECT: A/C Related Moan MODELS: 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country SYMPTOM/CONDITION: A moan noise is heard in 1400 - 2000 engine RPM range when the A/C compressor is engaged. This moan is the result of a resonance of components of the vehicle. DIAGNOSIS: Operate the engine in the 1400 - 2000 RPM range and engage the A/C compressor. If a moan noise is heard, perform the repair procedure. PARTS REQUIRED: 1 4773165 Clutch Plate, A/C with Damper Ring AR 4462924 Shim Package, A/C Compressor Clutch REPAIR PROCEDURE: This bulletin involves replacing the A/C clutch plate with one that incorporates a damper ring. NOTE: THIS REPAIR MAY NOT TOTALLY ELIMINATE THE MOAN BUT WILL REDUCE THE NOISE SIGNIFICANTLY. 1. Remove the screw attaching the coolant recovery bottle and set the bottle aside to improve access to the front of the A/C compressor. 2. Remove the compressor shaft bolt. A band type oil filter wrench can be placed around the clutch plate to aid in bolt removal. CAUTION: DO NOT USE ANY TYPE OF PRYING DEVICE BETWEEN THE CLUTCH PLATE AND THE PULLEY TO REMOVE THE CLUTCH PLATE AS DAMAGE TO THE CLUTCH PLATE OR PULLEY COULD RESULT. 3. Remove the clutch plate. It may be necessary to lightly tap the clutch plate with a plastic hammer in order to free it from the compressor shaft. 4. Remove the clutch shim(s) from the shaft and clutch plate. Reinstall the shim(s) in the new clutch plate. 5. Install the damper ring clutch plate (P/N 4773165) on the compressor shaft. 6. With the clutch plate pressed tight against the shim(s), measure the air gap between the clutch plate and the pulley face with a feeler gauge. The air gap should be .020 in. - .035 in. (0.5 mm - 0.9 mm). Adjust the shim pack if necessary to obtain the proper air gap using shims (P/N 4462924). 7. Install and torque the compressor shaft bolt to 135 - 175 In.Lbs. (15.5 - 19.5 N-m). 8. The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is still correct. Spin the pulley for the final check. 9. Reinstall the coolant recovery bottle. NOTE: BECAUSE THIS REPAIR PROCEDURE REPLACES ONLY THE A/C COMPRESSOR CLUTCH PLATE AND DOES NOT INCLUDE REPLACEMENT OF THE PULLEY, THE CLUTCH PULLEY BREAK-IN PROCEDURE OUTLINED IN THE SERVICE MANUAL MUST BE MODIFIED TO CYCLE THE A/C CLUTCH FIFTY (50) TIMES. OTHERWISE FOLLOW THE PROCEDURE EXACTLY. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch: > 242593 > Dec > 93 > A/C Compressor - Moaning Noise > Page 6984 10. Perform the CLUTCH BREAK-IN procedure outlined on page 24-18 of the 1993 Van/Wagon Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370-3105) or page 24-20 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 24-05-16-90 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch: > 242593 > Dec > 93 > A/C Compressor - Moaning Noise Compressor Clutch: All Technical Service Bulletins A/C Compressor - Moaning Noise NO.: 24-25-93 GROUP: Air Conditioning EFFECTIVE DATE: Dec. 31, 1993 SUBJECT: A/C Related Moan MODELS: 1993 - 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country SYMPTOM/CONDITION: A moan noise is heard in 1400 - 2000 engine RPM range when the A/C compressor is engaged. This moan is the result of a resonance of components of the vehicle. DIAGNOSIS: Operate the engine in the 1400 - 2000 RPM range and engage the A/C compressor. If a moan noise is heard, perform the repair procedure. PARTS REQUIRED: 1 4773165 Clutch Plate, A/C with Damper Ring AR 4462924 Shim Package, A/C Compressor Clutch REPAIR PROCEDURE: This bulletin involves replacing the A/C clutch plate with one that incorporates a damper ring. NOTE: THIS REPAIR MAY NOT TOTALLY ELIMINATE THE MOAN BUT WILL REDUCE THE NOISE SIGNIFICANTLY. 1. Remove the screw attaching the coolant recovery bottle and set the bottle aside to improve access to the front of the A/C compressor. 2. Remove the compressor shaft bolt. A band type oil filter wrench can be placed around the clutch plate to aid in bolt removal. CAUTION: DO NOT USE ANY TYPE OF PRYING DEVICE BETWEEN THE CLUTCH PLATE AND THE PULLEY TO REMOVE THE CLUTCH PLATE AS DAMAGE TO THE CLUTCH PLATE OR PULLEY COULD RESULT. 3. Remove the clutch plate. It may be necessary to lightly tap the clutch plate with a plastic hammer in order to free it from the compressor shaft. 4. Remove the clutch shim(s) from the shaft and clutch plate. Reinstall the shim(s) in the new clutch plate. 5. Install the damper ring clutch plate (P/N 4773165) on the compressor shaft. 6. With the clutch plate pressed tight against the shim(s), measure the air gap between the clutch plate and the pulley face with a feeler gauge. The air gap should be .020 in. - .035 in. (0.5 mm - 0.9 mm). Adjust the shim pack if necessary to obtain the proper air gap using shims (P/N 4462924). 7. Install and torque the compressor shaft bolt to 135 - 175 In.Lbs. (15.5 - 19.5 N-m). 8. The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is still correct. Spin the pulley for the final check. 9. Reinstall the coolant recovery bottle. NOTE: BECAUSE THIS REPAIR PROCEDURE REPLACES ONLY THE A/C COMPRESSOR CLUTCH PLATE AND DOES NOT INCLUDE REPLACEMENT OF THE PULLEY, THE CLUTCH PULLEY BREAK-IN PROCEDURE OUTLINED IN THE SERVICE MANUAL MUST BE MODIFIED TO CYCLE THE A/C CLUTCH FIFTY (50) TIMES. OTHERWISE FOLLOW THE PROCEDURE EXACTLY. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch: > 242593 > Dec > 93 > A/C Compressor - Moaning Noise > Page 6990 10. Perform the CLUTCH BREAK-IN procedure outlined on page 24-18 of the 1993 Van/Wagon Front Wheel Drive/All Wheel Drive Service Manual (Publication No. 81-370-3105) or page 24-20 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 24-05-16-90 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > Page 6991 Compressor Clutch: Testing and Inspection Compressor & Clutch Diagnosis (Part 2 of 2) COMPRESSOR CLUTCH TEST The air-conditioning compressor clutch electrical circuit is controlled by the engine controller computer. It is located in the engine compartment outboard of the battery. If the compressor clutch does not engage, Verify refrigerant charge. If the compressor clutch still does not engage, Check for battery voltage at the differential pressure cut-off switch located on the expansion valve. If voltage is detected at the cut-off switch, connect switch and check for battery voltage between the compressor clutch connector terminals. If voltage is detected, perform A/C Clutch Coil Tests. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > Page 6992 CLUTCH COIL TESTS 1. Verify battery state of charge. (Test indicator in battery should be green). 2. Connect an ammeter (0-10 ampere scale) in series with the clutch coil terminal. Use a volt meter (0-20 volt scale) with clip leads measuring voltage across the battery and A/C clutch. 3. With A/C control in A/C mode and blower at low speed, start the engine and run at normal idle. 4. The A/C clutch should engage immediately and the clutch voltage should be within two volts of the battery voltage. If the A/C clutch does not engage, test the fusible link. 5. The A/C clutch coil is acceptable if the current draw is 2.0 to 3.7 amperes at 11.5-12.5 volts at clutch coil. This is with the work area temperature at 21°C (70°F). If voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until voltage reads below 12.5 volts. If coil current reads zero, the coil is open and should be replaced. If the ammeter reading is 4 amperes or more, the coil is shorted and should be replaced. If the coil voltage is not within two volts of the battery voltage, test clutch coil feed circuit for excessive voltage drop. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > Page 6993 Compressor Clutch: Service and Repair Compressor Shaft Bolt And Clutch Plate REMOVAL NOTE: Compressor assembly must be removed from mounting. Although, refrigerant removal is not necessary. 1. Remove the compressor shaft bolt. A band type oil filter removal tool can be placed around the clutch plate to aid in bolt removal. CAUTION: Do not use screwdrivers between the clutch plate assembly and pulley to remove front plate as this may damage the front plate assembly. Clutch Plate And Shims 2. Tap the clutch plate with a plastic hammer and remove clutch plate and shim. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > Page 6994 Removing Pulley Snap Ring 3. Remove pulley retaining snap ring with snap ring pliers (C-4574), and slide pulley assembly off of compressor. 4. Remove coil wire clip screw and wire harness. Clutch Coil Snap Ring 5. Remove snap ring retaining field coil onto compressor housing. Slide field coil off of compressor housing. 6. Examine frictional faces of the clutch pulley and front plate for wear. The pulley and front plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft nose area of the compressor for oil and remove the felt from the front cover. If the compressor felt is saturated with oil, the shaft seal is leaking and will have to be replaced. 7. Check bearing for roughness, excessive leakage or grease. If grease from bearing has contaminated the faces of the pulley or front plate, they should be replaced. If the bearing is rough or binds, replace clutch pulley and front plate assembly. CAUTION: The clutch pulley and the front plate were mated at the factory by a burnishing operation. No attempt should be made to separately replace either part. This will result in clutch slippage due to insufficient contact area. INSTALLATION 1. Align pin in back of field coil with hole in compressor end housing, and position field coil into place. Make sure that lead wires are properly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > Page 6995 routed, and fasten with the wire clip screw. 2. Install field coil retaining snap ring with snap ring pliers. The bevel side of the snap ring facing outward. Also both snap ring eyelets must be to the right or left of the pin on compressor. Press snap ring to make sure it is properly seated in the groove. CAUTION: If snap ring is not fully seated it will vibrate out, resulting in a clutch failure and severe damage to the front face of the compressor. Installing Pulley Assembly 3. Install pulley assembly to compressor. If necessary; tap gently with a block of wood on the friction surface. CAUTION: Do not mar the pulley frictional surface. 4. Install pulley assembly retaining snap ring (bevel side outward) with snap ring pliers. Press the snap ring to make sure it is properly seated in the groove. 5. If the original front plate assembly and pulley assembly are to be reused, the old shim(s) can be used. If not, place a trial stack of shims, 1 mm (0.040 in.) thick, on the shaft against the shoulder. 6. Install front plate assembly onto shaft. 7. With the front plate assembly tight against the shim(s), measure the air gap between front plate and pulley face with feeler gauges. The air gap should be between 0.5 and 0.9 mm (0.020 and 0.035 inch) If proper air gap is not obtained, add or subtract shims until desired air gap is obtained. 8. Install compressor shaft bolt. Tighten to 15.5 to 19.5 Nm (135 to 175 in-lbs.). NOTE: Shims may compress after tightening shaft nut. Check air gap in four or more places to verify if air gap is still correct. Spin pulley for final check. CLUTCH BREAK-IN After a new clutch has been installed, check the voltage and amperage to the clutch (determine it to be satisfactory). Then cycle the A/C clutch approximately 20 times (5 sec. on and 5 sec. off). For this procedure, set the system to the A/C mode, using high blower, and engine rpm at 1500-2000. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher clutch torque capability. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair Compressor Clutch Coil: Service and Repair Compressor Shaft Bolt And Clutch Plate REMOVAL NOTE: Compressor assembly must be removed from mounting. Although, refrigerant removal is not necessary. 1. Remove the compressor shaft bolt. A band type oil filter removal tool can be placed around the clutch plate to aid in bolt removal. CAUTION: Do not use screwdrivers between the clutch plate assembly and pulley to remove front plate as this may damage the front plate assembly. Clutch Plate And Shims 2. Tap the clutch plate with a plastic hammer and remove clutch plate and shim. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 6999 Removing Pulley Snap Ring 3. Remove pulley retaining snap ring with snap ring pliers (C-4574), and slide pulley assembly off of compressor. 4. Remove coil wire clip screw and wire harness. Clutch Coil Snap Ring 5. Remove snap ring retaining field coil onto compressor housing. Slide field coil off of compressor housing. 6. Examine frictional faces of the clutch pulley and front plate for wear. The pulley and front plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft nose area of the compressor for oil and remove the felt from the front cover. If the compressor felt is saturated with oil, the shaft seal is leaking and will have to be replaced. 7. Check bearing for roughness, excessive leakage or grease. If grease from bearing has contaminated the faces of the pulley or front plate, they should be replaced. If the bearing is rough or binds, replace clutch pulley and front plate assembly. CAUTION: The clutch pulley and the front plate were mated at the factory by a burnishing operation. No attempt should be made to separately replace either part. This will result in clutch slippage due to insufficient contact area. INSTALLATION 1. Align pin in back of field coil with hole in compressor end housing, and position field coil into place. Make sure that lead wires are properly Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 7000 routed, and fasten with the wire clip screw. 2. Install field coil retaining snap ring with snap ring pliers. The bevel side of the snap ring facing outward. Also both snap ring eyelets must be to the right or left of the pin on compressor. Press snap ring to make sure it is properly seated in the groove. CAUTION: If snap ring is not fully seated it will vibrate out, resulting in a clutch failure and severe damage to the front face of the compressor. Installing Pulley Assembly 3. Install pulley assembly to compressor. If necessary; tap gently with a block of wood on the friction surface. CAUTION: Do not mar the pulley frictional surface. 4. Install pulley assembly retaining snap ring (bevel side outward) with snap ring pliers. Press the snap ring to make sure it is properly seated in the groove. 5. If the original front plate assembly and pulley assembly are to be reused, the old shim(s) can be used. If not, place a trial stack of shims, 1 mm (0.040 in.) thick, on the shaft against the shoulder. 6. Install front plate assembly onto shaft. 7. With the front plate assembly tight against the shim(s), measure the air gap between front plate and pulley face with feeler gauges. The air gap should be between 0.5 and 0.9 mm (0.020 and 0.035 inch) If proper air gap is not obtained, add or subtract shims until desired air gap is obtained. 8. Install compressor shaft bolt. Tighten to 15.5 to 19.5 Nm (135 to 175 in-lbs.). NOTE: Shims may compress after tightening shaft nut. Check air gap in four or more places to verify if air gap is still correct. Spin pulley for final check. CLUTCH BREAK-IN After a new clutch has been installed, check the voltage and amperage to the clutch (determine it to be satisfactory). Then cycle the A/C clutch approximately 20 times (5 sec. on and 5 sec. off). For this procedure, set the system to the A/C mode, using high blower, and engine rpm at 1500-2000. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher clutch torque capability. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7004 In Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7005 Compressor Clutch Relay: Description and Operation Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7006 In Power Distribution Center PURPOSE Supplies ground path for A/C compressor clutch. OPERATION Controlled by A/C or defrost switch (inside vehicle) and Powertrain Control Module (PCM). Relay receives battery voltage from radiator fan relay , (A/C relay will not energize unless the radiator fan relay is energized). When A/C or defrost is selected, (turned ON), inside vehicle, and low and high pressure switches are closed, PCM receives an A/C ON signal. PCM then supplies relay ground. If PCM senses Wide Open Throttle (WOT) or low idle speed condition, it removes relay ground, discontinueing A/C clutch engagement. PCM delays activation of A/C relay for a specific period after engine start-up. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications Condenser HVAC: Specifications The oil designated for this vehicle is ND8 PAG (polyalkalene glycol). Front A/C - Condenser 15 ml (0.5 oz) Dual A/C - Condenser 30 ml (1.0 oz) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 7010 Condenser HVAC: Service and Repair REMOVAL WARNING: The refrigeration system must be completely empty before proceeding with this operation. NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. 1. Disconnect condenser to drier line at condenser side. 2. Remove radiator fan and shroud assembly. 3. Remove condenser outlet to radiator bracket. 4. Remove grill assembly. 5. Remove core support center brace. 6. Remove auxiliary transmission oil cooler, if equipped. 7. Remove right side headlamp assembly. 8. Remove core support plastic panel. 9. Remove condenser mounting bolts. 10. Remove condenser from vehicle. INSTALLATION 1. To install, replace all 0-rings and gaskets, coat all sealing surfaces with approved wax-free refrigerant oil. Then reverse the preceding operation. 2. Evacuate and charge system. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Component Information > Locations Condenser Fan: Locations Engine Compartment Component. RH Front Of Engine Compartment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Engine Compartment Components RH Side Of Engine Compartment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 241194 > Jul > 94 > A/C, Heater - Temperature Lever Difficult to Move Control Assembly: Customer Interest A/C, Heater - Temperature Lever Difficult to Move NO: 24-11-94 GROUP: Heater & A/C DATE: Jul. 1, 1994 SUBJECT: A/C Heater Blend Air Door Sticking MODELS: 1989 - 1994 (AS) Town & Country/Caravan/Voyager 1984 - 1988 (S) Caravan/Voyager SYMPTOM/CONDITION: Poor heater performance, or poor A/C performance, and/or temperature control lever difficult or impossible to move. DIAGNOSIS: Check the temperature control lever for a binding condition. If the lever is difficult or impossible to move, perform the repair procedure. PARTS REQUIRED: AR 4318039 Mopar Rust Penetrant AR 4318066 Mopar White Spray Lube REPAIR PROCEDURE: This bulletin involves accessing the lower pivot and contact surfaces of the blend air door shaft to apply rust penetrant to free up the shaft and then apply lubricant to prevent further corrosion. 1. Remove the center floor console on vehicles so equipped. 2. Remove the floor air distribution duct. 3. On the extension which houses the blend air door shaft inside the heater-A/C housing (Refer to Illustration), drill a 3/32 in. (2.2 mm) hole perpendicular to the side of the extension and 3/8 in. (10 mm) up from the bottom of the extension to gain access to the blend air door shaft. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 241194 > Jul > 94 > A/C, Heater - Temperature Lever Difficult to Move > Page 7025 4. Spray a sufficient amount of Mopar Rust Penetrant into the hole drilled in step 3 and work the temperature control lever until it moves freely. 5. When the door moves freely, inject Mopar White Spray Lube into the hole for two seconds time in order to prevent further binding/sticking in this area. 6. Wipe the housing exterior clean of any excess lubricant and tape over hole in extension with black duct tape. 7. Install floor air distribution duct. 8. Install center floor console if equipped. 9. If movement of the temperature control lever is still difficult, inspect the temperature control cable where it attaches to the control for kinks. If kinked replace the temperature control cable. Refer to the appropriate service manual for cable replacement procedure, and the appropriate Labor Operation Time Schedule Manual for cable replacement time allowance. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 1984 - 1993 24-65-20-90 0.4 Hrs. 1994 24-65-20-91 0.6 Hrs. Center Floor Console (if Equipped) 24-65-20-60 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 241194 > Jul > 94 > A/C, Heater Temperature Lever Difficult to Move Control Assembly: All Technical Service Bulletins A/C, Heater - Temperature Lever Difficult to Move NO: 24-11-94 GROUP: Heater & A/C DATE: Jul. 1, 1994 SUBJECT: A/C Heater Blend Air Door Sticking MODELS: 1989 - 1994 (AS) Town & Country/Caravan/Voyager 1984 - 1988 (S) Caravan/Voyager SYMPTOM/CONDITION: Poor heater performance, or poor A/C performance, and/or temperature control lever difficult or impossible to move. DIAGNOSIS: Check the temperature control lever for a binding condition. If the lever is difficult or impossible to move, perform the repair procedure. PARTS REQUIRED: AR 4318039 Mopar Rust Penetrant AR 4318066 Mopar White Spray Lube REPAIR PROCEDURE: This bulletin involves accessing the lower pivot and contact surfaces of the blend air door shaft to apply rust penetrant to free up the shaft and then apply lubricant to prevent further corrosion. 1. Remove the center floor console on vehicles so equipped. 2. Remove the floor air distribution duct. 3. On the extension which houses the blend air door shaft inside the heater-A/C housing (Refer to Illustration), drill a 3/32 in. (2.2 mm) hole perpendicular to the side of the extension and 3/8 in. (10 mm) up from the bottom of the extension to gain access to the blend air door shaft. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 241194 > Jul > 94 > A/C, Heater Temperature Lever Difficult to Move > Page 7031 4. Spray a sufficient amount of Mopar Rust Penetrant into the hole drilled in step 3 and work the temperature control lever until it moves freely. 5. When the door moves freely, inject Mopar White Spray Lube into the hole for two seconds time in order to prevent further binding/sticking in this area. 6. Wipe the housing exterior clean of any excess lubricant and tape over hole in extension with black duct tape. 7. Install floor air distribution duct. 8. Install center floor console if equipped. 9. If movement of the temperature control lever is still difficult, inspect the temperature control cable where it attaches to the control for kinks. If kinked replace the temperature control cable. Refer to the appropriate service manual for cable replacement procedure, and the appropriate Labor Operation Time Schedule Manual for cable replacement time allowance. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 1984 - 1993 24-65-20-90 0.4 Hrs. 1994 24-65-20-91 0.6 Hrs. Center Floor Console (if Equipped) 24-65-20-60 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 7032 Control Assembly: Locations Instrument Panel Components & Connectors Center Of Instrument Panel Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 7033 Control Assembly: Service and Repair A/C AND HEATER CONTROL / BLOWER SWITCH REMOVAL (1) Remove the Center Instrument Panel Cluster Bezel. (2) Remove cigar lighter element. (3) Remove two screws and pull control assembly rearward. Reach behind control and disconnect the wiring harnesses, vacuum lines and temperature control cable (Fig. 1O) Remove switch. (4) For installation reverse above procedures. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor Evaporator Case: Customer Interest Air Conditioning Ducts - Emits Musty Odor NO: 24-06-95 Rev. A GROUP: Heater & A/C DATE: May 26, 1995 SUBJECT: Air Conditioning Ducts Emit Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 DATED MAY 5, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NUMBERS HAVE BEEN CORRECTED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1994 - 1995 (AB) Ram Van/Wagon (Built On or After Aug. 1, 1993 - MDH 08-01-XX) 1992 - 1993 (AC) Dynasty/New Yorker Salon (Built On or After Jan. 31, 1992 - MDH 01-31 -XX) 1993 - 1995 (AN) Dakota 1992 - 1995 (AS) Caravan/Voyager/Town & Country 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built On or After Jan. 31, 1992 - MDH 01-31-XX) 1994 - 1995 (BR) Ram Truck 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concord/Intrepid/LHS/New Yorker/Vision 1995 (PL) Neon 1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicles may emit a "musty" odor from the air conditioning ducts. The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related odors are possible, and are covered separately below: CAUSE AND CORRECTION - VEHICLES IN SERVICE LESS THAN 12 MONTHS On some vehicles with "plate fin" A/C evaporators, the manufacturing process occasionally results in an excessive amount of corrosion protection coating being applied on the evaporator external surfaces. A heavy coating can result in an odor from the evaporator fins, especially when dry fins become wet from condensation. A new coating has been developed to correct this condition. The evaporator coil in the A/C unit must be replaced. Proceed to Repair Procedure A. CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended use resulting from possible accumulation of "foreign matter" in the AC unit. This condition is more likely to occur in vehicles that have been in extended use in humid climates. To correct this condition, the internal surfaces of the A/C air handling system will have to be cleaned. Proceed to Repair Procedure B. PARTS AND EQUIPMENT REQUIRED: REPAIR PROCEDURE A - VEHICLES IN SERVICE LESS THAN 12 MONTHS AR 4798625 Coil, A/C Evaporator (AB 1994-1995, Vehicles Built On or After Aug. 1,1993) AR 4677011 Coil, A/C Evaporator (AC/AY 1992-1993, Vehicles Built On or After Jan. 31,1992) AR 4798624 Coil, A/C Evaporator (AN 1993-1995) AR 4723069 Coil, A/C Evaporator (AS 1992) AR 4734292 Coil, A/C Evaporator (AS 1993-1994) AR 4797131 Coil, A/C Evaporator (AS 1995) AR 4723518 Coil, A/C Evaporator (BR 1994) AR 4798705 Coil, A/C Evaporator (BR 1995) AR 4644790 Coil, A/C Evaporator (JA 1995) AR 4797129 Coil, A/C Evaporator (LH 1993-1995) AR 4797130 Coil, A/C Evaporator (PL 1995) AR 4723518 Coil, A/C Evaporator (ZJ 1993-1994) AR 4798705 Coil, A/C Evaporator (ZJ 1995) REPAIR PROCEDURE B - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1 4728942 A/C Evaporator Cleaner 1 4740319 Reusable Applicator 1 NPN Pair of Rubber Gloves 1 NPN Pair of Safety Glasses REPAIR PROCEDURE A: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 7042 This repair involves checking the A/C condensation drain tube for proper operation and replacing the A/C evaporator coil. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. 2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts and Equipment Required section. Follow all evaporator removal and replacement instructions listed in the appropriate vehicle Service Manual. REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper operation and cleaning and disinfecting the A/C evaporator coil and housing. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. NOTE: FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE WATER TO FLUSH EYES IF NECESSARY 2. Protect the interior of the vehicle with a drop cloth. 3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the evaporator coil. NOTE: FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM. 4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the dash panel). Open the vehicle doors. On AS Body models, remove the resistor block. NOTE: ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT. 6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319. 7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty. Spray into the resistor block opening on "AS" models. 8. Turn the vehicle OFF and allow to soak for at least 30 minutes. 9. Wipe off any excess cleaner from around the instrument panel ducts. 10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle for 20 minutes to dry the system. NOTE: FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE ODOR PROBLEM. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-95 Evaporator, Replace 1994 (AB) 2.7 Hrs. 1995 (AB) 1.9 Hrs. 1992-93 (AC/AY) 2.0 Hrs. 1993-95 (AN) 2.2 Hrs. 1992-93 (AS) 2.4 Hrs. 1994-95 (AS) 3.8 Hrs. 1994-95 (BR) 3.3 Hrs. **1995 (JA) 3.7 Hrs.** 1993 (LH) 4.1 Hrs. 1994-95 (LH) 3.4 Hrs. 1995 (PL) 3.9 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 7043 1993-95 (ZJ) 3.1 Hrs. Optional Equipment 24-65-02-60 Console Equipped 1992-93 (AS) 0.2 Hrs. 1993-95 (LH) 0.2 Hrs. 24-65-02-66 50/50 Bench Seat 1993-95 (LH) 0.8 Hrs. FAILURE CODE: P8 - New Part **24-65-02-94** Evaporator, Clean and Disinfect 0.7 Hrs. FAILURE CODE: YP - Odor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor Evaporator Case: All Technical Service Bulletins Air Conditioning Ducts - Emits Musty Odor NO: 24-06-95 Rev. A GROUP: Heater & A/C DATE: May 26, 1995 SUBJECT: Air Conditioning Ducts Emit Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 DATED MAY 5, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NUMBERS HAVE BEEN CORRECTED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1994 - 1995 (AB) Ram Van/Wagon (Built On or After Aug. 1, 1993 - MDH 08-01-XX) 1992 - 1993 (AC) Dynasty/New Yorker Salon (Built On or After Jan. 31, 1992 - MDH 01-31 -XX) 1993 - 1995 (AN) Dakota 1992 - 1995 (AS) Caravan/Voyager/Town & Country 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built On or After Jan. 31, 1992 - MDH 01-31-XX) 1994 - 1995 (BR) Ram Truck 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concord/Intrepid/LHS/New Yorker/Vision 1995 (PL) Neon 1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicles may emit a "musty" odor from the air conditioning ducts. The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related odors are possible, and are covered separately below: CAUSE AND CORRECTION - VEHICLES IN SERVICE LESS THAN 12 MONTHS On some vehicles with "plate fin" A/C evaporators, the manufacturing process occasionally results in an excessive amount of corrosion protection coating being applied on the evaporator external surfaces. A heavy coating can result in an odor from the evaporator fins, especially when dry fins become wet from condensation. A new coating has been developed to correct this condition. The evaporator coil in the A/C unit must be replaced. Proceed to Repair Procedure A. CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended use resulting from possible accumulation of "foreign matter" in the AC unit. This condition is more likely to occur in vehicles that have been in extended use in humid climates. To correct this condition, the internal surfaces of the A/C air handling system will have to be cleaned. Proceed to Repair Procedure B. PARTS AND EQUIPMENT REQUIRED: REPAIR PROCEDURE A - VEHICLES IN SERVICE LESS THAN 12 MONTHS AR 4798625 Coil, A/C Evaporator (AB 1994-1995, Vehicles Built On or After Aug. 1,1993) AR 4677011 Coil, A/C Evaporator (AC/AY 1992-1993, Vehicles Built On or After Jan. 31,1992) AR 4798624 Coil, A/C Evaporator (AN 1993-1995) AR 4723069 Coil, A/C Evaporator (AS 1992) AR 4734292 Coil, A/C Evaporator (AS 1993-1994) AR 4797131 Coil, A/C Evaporator (AS 1995) AR 4723518 Coil, A/C Evaporator (BR 1994) AR 4798705 Coil, A/C Evaporator (BR 1995) AR 4644790 Coil, A/C Evaporator (JA 1995) AR 4797129 Coil, A/C Evaporator (LH 1993-1995) AR 4797130 Coil, A/C Evaporator (PL 1995) AR 4723518 Coil, A/C Evaporator (ZJ 1993-1994) AR 4798705 Coil, A/C Evaporator (ZJ 1995) REPAIR PROCEDURE B - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1 4728942 A/C Evaporator Cleaner 1 4740319 Reusable Applicator 1 NPN Pair of Rubber Gloves 1 NPN Pair of Safety Glasses REPAIR PROCEDURE A: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 7049 This repair involves checking the A/C condensation drain tube for proper operation and replacing the A/C evaporator coil. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. 2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts and Equipment Required section. Follow all evaporator removal and replacement instructions listed in the appropriate vehicle Service Manual. REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper operation and cleaning and disinfecting the A/C evaporator coil and housing. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. NOTE: FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE WATER TO FLUSH EYES IF NECESSARY 2. Protect the interior of the vehicle with a drop cloth. 3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the evaporator coil. NOTE: FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM. 4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the dash panel). Open the vehicle doors. On AS Body models, remove the resistor block. NOTE: ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT. 6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319. 7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty. Spray into the resistor block opening on "AS" models. 8. Turn the vehicle OFF and allow to soak for at least 30 minutes. 9. Wipe off any excess cleaner from around the instrument panel ducts. 10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle for 20 minutes to dry the system. NOTE: FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE ODOR PROBLEM. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-95 Evaporator, Replace 1994 (AB) 2.7 Hrs. 1995 (AB) 1.9 Hrs. 1992-93 (AC/AY) 2.0 Hrs. 1993-95 (AN) 2.2 Hrs. 1992-93 (AS) 2.4 Hrs. 1994-95 (AS) 3.8 Hrs. 1994-95 (BR) 3.3 Hrs. **1995 (JA) 3.7 Hrs.** 1993 (LH) 4.1 Hrs. 1994-95 (LH) 3.4 Hrs. 1995 (PL) 3.9 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 7050 1993-95 (ZJ) 3.1 Hrs. Optional Equipment 24-65-02-60 Console Equipped 1992-93 (AS) 0.2 Hrs. 1993-95 (LH) 0.2 Hrs. 24-65-02-66 50/50 Bench Seat 1993-95 (LH) 0.8 Hrs. FAILURE CODE: P8 - New Part **24-65-02-94** Evaporator, Clean and Disinfect 0.7 Hrs. FAILURE CODE: YP - Odor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Case: > 085394 > Oct > 94 > Engine Starter - Intermittent No Crank Battery Cable: All Technical Service Bulletins Engine Starter - Intermittent No Crank NO: 08-53-94 GROUP: Electrical DATE: Oct. 7, 1994 SUBJECT: Intermittent No Crank MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Engine intermittently will not crank. DIAGNOSIS: Inspect the battery to starter cable connection at the starter (Refer to Illustration). If the terminal is not fully seated, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves modifying the battery to starter cable terminal insulator at the starter connection. 1. Record the customers preset radio station selections. 2. Disconnect the ground cable from the battery. 3. Remove the battery to starter cable from the starter. 4. Grind off hard plastic material 1/8 - 5/16 in. (3 - 5 mm) as shown in the illustration. 5. Place battery to starter cable on the starter. Make sure the terminal seats flat as shown in the illustration. If the terminal does not seat flush, grind off more plastic until the terminal can seat flush. 6. Connect the battery to starter cable to the starter. Torque the nut to 75 in.lbs. (9 N-m). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Case: > 085394 > Oct > 94 > Engine Starter - Intermittent No Crank > Page 7056 7. Connect the ground cable to the battery. 8. Reprogram the customers preset radio stations and set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-12-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Case: > 085394 > Oct > 94 > Engine Starter - Intermittent No Crank > Page 7062 7. Connect the ground cable to the battery. 8. Reprogram the customers preset radio stations and set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-12-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Page 7063 Evaporator Case: Service and Repair NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. REMOVAL AND INSTALLATION WARNING: If equipped with air conditioning, the refrigeration system must be completely empty before proceeding. CAUTION: Disconnect battery negative cable, in engine compartment, before servicing instrument panel. 1. Set parking brake. 2. Disconnect battery negative cable. 3. Using a refrigerant recovery machine, remove refrigerant from the A/C system. 4. Disconnect all engine compartment lines and vacuum hoses. 5. Drain engine coolant. Plug coolant lines. INSTRUMENT PANEL CLUSTER BEZEL 1. To remove top cover use a flat blade tool. Pry up on either end and continue across the full length of the top cover. 2. To remove cluster bezel grille use the removal tool. Using tool at either end pull up and remove grille. 3. Remove six mounting screws from the hood and message center assembly. Using a flat blade tool pry up on either end and remove module and disconnect wire connector. 4. Reach behind lower right corner of center bezel and pull to disconnect attaching clip. Repeat in all of the corners and remove bezel. Disconnect ash receiver wire and lamp assembly if equipped. 5. Remove three instrument cluster bezel screws on the bottom of bezel and three at the upper left. Pulling up and rearward on the top edge of bezel remove bezel. 6. Disconnect POD switches wiring connectors. LOWER RIGHT INSTRUMENT PANEL Steering Column Cover 1. Remove steering column cover. 2. Remove premium console. 3. Remove center trim bezel. Remove ash receiver lamp and socket if equipped. 4. Remove A/C heater control. 5. Disconnect cigar lighter. 6. Remove screw in air duct. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Page 7064 Glove Box 7. Remove attaching screws and right lower panel. Screw location: - One screw outboard right of lower panel - Two screws in ash receiver/cupholder opening - Two screws bottom on the lower right - One screw in heater duct above heater control. - Remove glove box attaching screws and disconnect check straps. - Disconnect glove box lamp. INSTRUMENT PANEL REMOVAL WARNING: Chock wheels when instrument panel is to be rolled down. The steering column is removed and transmission may be out of park. Release the park brake before the release cable is disconnected. Disconnecting park brake cable while park brake is engaged may cause personal injury. Silencer Panel 1. Remove lower left instrument panel silencer. 2. Set parking brake and shift gear selector into low. 3. Remove lower left reinforcement. 4. Disconnect transmission range indicator at column. 5. Unhook transmission range indicator cable eyelet from column actuating arm: - Release column insert lock tab. - Squeeze legs together and lift insert from steering column, leave insert free. - Place cable on instrument panel to avoid transmission range indicator cable damage during removal. 6. Remove steering column. See: Steering and Suspension/Steering/Steering Column/Service and Repair 7. Remove lower right instrument panel silencer. 8. Remove floor braces. 9. Remove A-pillar intermediate and sill scuff garnish moldings. 10. Unfasten the hood release mechanism from the side cowl. 11. Disconnect the brake light switch, parking brake switch and bulk head wiring connectors. 12. Under the hood disconnect the ABS connector and resistor block. Unseat the grommet at the dash panel and feed wiring back into passenger compartment. 13. Remove the two nuts, securing the instrument panel, at the steering column support brace. 14. Loosen the instrument panel roll up bolts. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Page 7065 15. Remove the six screws securing the instrument panel at the fence line. 16. Roll the instrument panel back and hang it from the short position of the roll up hook. 17. With instrument panel hanging in the short position disconnect the left side body wiring connections. 18. Roll the instrument panel to the long position on the roll up hook and perform the following operations: - Disconnect the antenna cable. - Disconnect the blower motor lead connection. - Disconnect the temperature control cable from the A/C or heater unit. - Disconnect the vacuum lines from the climate control assembly - Disconnect the right side body wiring connectors. 19. Remove instrument panel from vehicle. 20. Disconnect the A/C unit hanger strap from the unit and temporarily reposition. 21. Remove the rubber condensate drain tube (in engine compartment). 22. Remove the four nuts (in the engine compartment) securing the unit to the dash panel. 23. Pull the entire unit rearward until the studs on the unit clear the dash panel. Drop the unit down. Pull it rearward to remove it from vehicle. To install the assembly, reverse the preceding operation. NOTE: When installing cluster, do not kink or bind transmission range indicator guide tube and position guide tube in original location. Move shift lever to Neutral (N) and note pointer location. Move shift lever to D, L and P note pointer location. Adjust, if necessary to center pointer on N. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor Evaporator Core: Customer Interest Air Conditioning Ducts - Emits Musty Odor NO: 24-06-95 Rev. A GROUP: Heater & A/C DATE: May 26, 1995 SUBJECT: Air Conditioning Ducts Emit Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 DATED MAY 5, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NUMBERS HAVE BEEN CORRECTED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1994 - 1995 (AB) Ram Van/Wagon (Built On or After Aug. 1, 1993 - MDH 08-01-XX) 1992 - 1993 (AC) Dynasty/New Yorker Salon (Built On or After Jan. 31, 1992 - MDH 01-31 -XX) 1993 - 1995 (AN) Dakota 1992 - 1995 (AS) Caravan/Voyager/Town & Country 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built On or After Jan. 31, 1992 - MDH 01-31-XX) 1994 - 1995 (BR) Ram Truck 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concord/Intrepid/LHS/New Yorker/Vision 1995 (PL) Neon 1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicles may emit a "musty" odor from the air conditioning ducts. The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related odors are possible, and are covered separately below: CAUSE AND CORRECTION - VEHICLES IN SERVICE LESS THAN 12 MONTHS On some vehicles with "plate fin" A/C evaporators, the manufacturing process occasionally results in an excessive amount of corrosion protection coating being applied on the evaporator external surfaces. A heavy coating can result in an odor from the evaporator fins, especially when dry fins become wet from condensation. A new coating has been developed to correct this condition. The evaporator coil in the A/C unit must be replaced. Proceed to Repair Procedure A. CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended use resulting from possible accumulation of "foreign matter" in the AC unit. This condition is more likely to occur in vehicles that have been in extended use in humid climates. To correct this condition, the internal surfaces of the A/C air handling system will have to be cleaned. Proceed to Repair Procedure B. PARTS AND EQUIPMENT REQUIRED: REPAIR PROCEDURE A - VEHICLES IN SERVICE LESS THAN 12 MONTHS AR 4798625 Coil, A/C Evaporator (AB 1994-1995, Vehicles Built On or After Aug. 1,1993) AR 4677011 Coil, A/C Evaporator (AC/AY 1992-1993, Vehicles Built On or After Jan. 31,1992) AR 4798624 Coil, A/C Evaporator (AN 1993-1995) AR 4723069 Coil, A/C Evaporator (AS 1992) AR 4734292 Coil, A/C Evaporator (AS 1993-1994) AR 4797131 Coil, A/C Evaporator (AS 1995) AR 4723518 Coil, A/C Evaporator (BR 1994) AR 4798705 Coil, A/C Evaporator (BR 1995) AR 4644790 Coil, A/C Evaporator (JA 1995) AR 4797129 Coil, A/C Evaporator (LH 1993-1995) AR 4797130 Coil, A/C Evaporator (PL 1995) AR 4723518 Coil, A/C Evaporator (ZJ 1993-1994) AR 4798705 Coil, A/C Evaporator (ZJ 1995) REPAIR PROCEDURE B - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1 4728942 A/C Evaporator Cleaner 1 4740319 Reusable Applicator 1 NPN Pair of Rubber Gloves 1 NPN Pair of Safety Glasses REPAIR PROCEDURE A: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 7074 This repair involves checking the A/C condensation drain tube for proper operation and replacing the A/C evaporator coil. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. 2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts and Equipment Required section. Follow all evaporator removal and replacement instructions listed in the appropriate vehicle Service Manual. REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper operation and cleaning and disinfecting the A/C evaporator coil and housing. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. NOTE: FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE WATER TO FLUSH EYES IF NECESSARY 2. Protect the interior of the vehicle with a drop cloth. 3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the evaporator coil. NOTE: FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM. 4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the dash panel). Open the vehicle doors. On AS Body models, remove the resistor block. NOTE: ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT. 6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319. 7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty. Spray into the resistor block opening on "AS" models. 8. Turn the vehicle OFF and allow to soak for at least 30 minutes. 9. Wipe off any excess cleaner from around the instrument panel ducts. 10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle for 20 minutes to dry the system. NOTE: FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE ODOR PROBLEM. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-95 Evaporator, Replace 1994 (AB) 2.7 Hrs. 1995 (AB) 1.9 Hrs. 1992-93 (AC/AY) 2.0 Hrs. 1993-95 (AN) 2.2 Hrs. 1992-93 (AS) 2.4 Hrs. 1994-95 (AS) 3.8 Hrs. 1994-95 (BR) 3.3 Hrs. **1995 (JA) 3.7 Hrs.** 1993 (LH) 4.1 Hrs. 1994-95 (LH) 3.4 Hrs. 1995 (PL) 3.9 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 7075 1993-95 (ZJ) 3.1 Hrs. Optional Equipment 24-65-02-60 Console Equipped 1992-93 (AS) 0.2 Hrs. 1993-95 (LH) 0.2 Hrs. 24-65-02-66 50/50 Bench Seat 1993-95 (LH) 0.8 Hrs. FAILURE CODE: P8 - New Part **24-65-02-94** Evaporator, Clean and Disinfect 0.7 Hrs. FAILURE CODE: YP - Odor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 241294 > Jul > 94 > A/C Evaporator - High Pitched Whistle Noise Evaporator Core: Customer Interest A/C Evaporator - High Pitched Whistle Noise NO: 24-12-94 GROUP: Heater & A/C DATE: Jul. 8, 1994 SUBJECT: A/C Evaporator High Pitch Whistle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-30-93, DATED DEC. 3, 1993. THIS IS A COMPLETE REVISION, AND COPIES OF TECHNICAL SERVICE BULLETIN 24-30-93 IN YOUR FILES AND/OR THE 1993 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-94000), SHOULD BE NOTED TO REFER TO TECHNICAL SERVICE BULLETIN 24-12-94. MODELS: 1993 - 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH P/N 4677203 EXPANSION VALVES. THE PART NUMBER IS STAMPED ON THE EXPANSION VALVE NEXT TO THE LOW PRESSURE CUT-OUT SWITCH. A DIFFERENT TYPE OF EXPANSION VALVE HAS BEEN USED IN VEHICLE PRODUCTION SINCE APPROXIMATELY 11/93 FOR 2.5L ENGINE EQUIPPED VEHICLES, 3/94 FOR 3.3L AND 3.8L ENGINE EQUIPPED VEHICLES. THE DIFFERENT TYPE OF EXPANSION VALVE WILL BE USED AT THE START OF THE 1995 MODEL YEAR FOR 3.0L ENGINE EQUIPPED VEHICLES. SYMPTOM/CONDITION: Under certain conditions, the internal flow of R-134a refrigerant may set up a resonance in some evaporator cores. This resonance can emit from the dash area as a high-pitched whistle noise. The whistle noise usually lasts 3 to 5 seconds and starts shortly after the A/C compressor clutch engages. The duration and the intensity of the whistle noise may vary as well as be highly intermittent. The whistle noise is most likely to be experienced in ambient temperatures above 85 degrees Fahrenheit and engine speeds around 2000 RPM. DIAGNOSIS: Diagnosis may be very difficult due to the intermittent nature of the whistle condition. If ambient temperatures in excess of 85 degrees Fahrenheit are not present for test drive purposes, have the vehicle owner describe in detail the condition(s) in which they experience their concern to determine if this bulletin applies. PARTS REQUIRED: 1 4677334 Valve, A/C Expansion 1 4677045 Gasket, A/C Expansion Valve To Evaporator 1 3846834 Gasket, A/C Expansion Valve To Refrigerant Line REPAIR PROCEDURE: This bulletin involves installing a different type of expansion valve. 1. Recover the R-134a refrigerant while completely discharging the A/C system. WARNING: THE A/C SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS OPERATION. 2. Remove the boot-type wire connector from the low pressure cut-off switch. 3. Remove the 3-pin connector from the Electronic Cycling Clutch Switch (ECCS). 4. Remove the bolt in the center of the refrigerant line sealing plate. 5. Carefully pull the refrigerant line sealing plate from the expansion valve. 6. Cover the openings on refrigerant line sealing plate to prevent contamination. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 241294 > Jul > 94 > A/C Evaporator - High Pitched Whistle Noise > Page 7080 7. Remove the two screws attaching the expansion valve to the evaporator sealing plate. 8. Carefully remove the expansion valve and the two aluminum gaskets. 9. Place a new gasket (P/N 4677045) on the evaporator sealing plate. 10. Carefully hold the new expansion valve (P/N 4677334) to the evaporator sealing plate, DO NOT SCRATCH THE SEALING SURFACES. Install the two attaching screws and torque to 70 130 in.lbs. (8-14 N-m). 11. Place a new gasket (P/N 3846834) on the refrigerant line sealing plate. 12. Carefully hold the refrigerant line sealing plate to the expansion valve, DO NOT SCRATCH THE SEALING SURFACES. Install the attaching bolt and torque to 170 - 230 in.lbs. (20 - 26 N-m.). 13. Connect the wire connectors to the low pressure cut-off switch and the ECCS. 14. Evacuate and recharge the A/C system. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-35-20-90 0.8 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 242193 > Sep > 93 > AC Ducts - Emit Odors Evaporator Core: Customer Interest AC Ducts - Emit Odors NO.: 24-21-93 GROUP: Air Conditioning DATE: Sep. 3, 1993 SUBJECT: Air Conditioning Ducts Emits Odor NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-12-92. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** MODELS: 1992**- 1993** (AC) Dynasty/New Yorker Salon (built after Jan. 31, 1992 - MDH 0131XX) 1992**- 1994** (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1992**- 1993** (AY) Imperial/New Yorker Fifth Avenue (built after Jan. 31, 1992 - MDH 0131XX) SYMPTOM/CONDITION: Some vehicles may emit an odor from the air conditioning ducts. The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related odors are possible, and are covered separately below: CAUSE AND CORRECTION - VEHICLES WITH LESS THAN 12,000 MILES **On some vehicles with the plate fin A/C evaporator, the manufacturing process occasionally results in an excessive amount of corrosion protection coating being applied on the evaporator external surfaces.** A heavy coating can result in an odor from the evaporator fins, especially when dry fins become wet from condensation. To correct this condition, the evaporator coil in the A/C unit must be replaced. Refer to the appropriate service manual for the replacement procedure. CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended use resulting from possible accumulation of foreign matter in the A/C unit. This condition is more likely to occur in vehicles that have been in extended use in humid climates. To correct this condition, the internal surfaces of the A/C air handling system will have to be cleaned by the repair procedure outlined in this bulletin. PARTS AND EQUIPMENT REQUIRED: VEHICLES WITH LESS THAN 12,000 MILES 1 Coil, A/C Evaporator AS 1992 4723069 AS 1993 - 1994 4474842 AC & AY 4677011 VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1 A/C Evaporator Cleaner 4728942 1 Reusable Applicator 4740319 1 Pair Of Rubber Gloves 1 Pair Of Safety Glasses REPAIR PROCEDURE: This bulletin involves cleaning and disinfecting the A/C evaporator and housing. NOTE: FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR CLEANER. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 242193 > Sep > 93 > AC Ducts - Emit Odors > Page 7085 - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE WATER TO FLUSH EYES IF NECESSARY 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Correct if necessary. 2. Protect the interior of the vehicle with a drop cloth. 3. Start the engine, set the blower on HIGH, air on recirculate, turn the A/C compressor OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the evaporator coil. 4. Switch to outside air. With a shop rag, block about 90% of the outside air inlet to increase air velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the dash panel). Open the vehicles doors. On "AS" Body models, remove the resistor block. **NOTE: THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING THE SCREWS COUNTER-CLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT.** 5. Shake the bottle of evaporator cleaner. Connect the bottle and a compressed air supply, with at least 80 PSI of pressure, to the reusable applicator. 6. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty. Spray into the resistor block opening on "AS" models. 7. Turn the vehicle OFF and allow to soak for at least 30 minutes. 8. Wipe off any excess cleaner from around the instrument panel ducts. 9. Start the engine, set the blower on HIGH, air on recirculate, **turn the A/C compressor OFF, open all of the instrument panel ducts, and open all of the vehicles windows.** Run the vehicle for 20 minutes to dry the system. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. Replace Evaporator AC & AY 1992 - 1993 24-65-90-91 2.0 Hrs. AS 1992 - 1994 24-65-90-91 2.4 Hrs. Clean Evaporator AC, AS & AY 24-65-90-90 0.3 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor Evaporator Core: All Technical Service Bulletins Air Conditioning Ducts - Emits Musty Odor NO: 24-06-95 Rev. A GROUP: Heater & A/C DATE: May 26, 1995 SUBJECT: Air Conditioning Ducts Emit Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 DATED MAY 5, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NUMBERS HAVE BEEN CORRECTED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1994 - 1995 (AB) Ram Van/Wagon (Built On or After Aug. 1, 1993 - MDH 08-01-XX) 1992 - 1993 (AC) Dynasty/New Yorker Salon (Built On or After Jan. 31, 1992 - MDH 01-31 -XX) 1993 - 1995 (AN) Dakota 1992 - 1995 (AS) Caravan/Voyager/Town & Country 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built On or After Jan. 31, 1992 - MDH 01-31-XX) 1994 - 1995 (BR) Ram Truck 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concord/Intrepid/LHS/New Yorker/Vision 1995 (PL) Neon 1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicles may emit a "musty" odor from the air conditioning ducts. The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related odors are possible, and are covered separately below: CAUSE AND CORRECTION - VEHICLES IN SERVICE LESS THAN 12 MONTHS On some vehicles with "plate fin" A/C evaporators, the manufacturing process occasionally results in an excessive amount of corrosion protection coating being applied on the evaporator external surfaces. A heavy coating can result in an odor from the evaporator fins, especially when dry fins become wet from condensation. A new coating has been developed to correct this condition. The evaporator coil in the A/C unit must be replaced. Proceed to Repair Procedure A. CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended use resulting from possible accumulation of "foreign matter" in the AC unit. This condition is more likely to occur in vehicles that have been in extended use in humid climates. To correct this condition, the internal surfaces of the A/C air handling system will have to be cleaned. Proceed to Repair Procedure B. PARTS AND EQUIPMENT REQUIRED: REPAIR PROCEDURE A - VEHICLES IN SERVICE LESS THAN 12 MONTHS AR 4798625 Coil, A/C Evaporator (AB 1994-1995, Vehicles Built On or After Aug. 1,1993) AR 4677011 Coil, A/C Evaporator (AC/AY 1992-1993, Vehicles Built On or After Jan. 31,1992) AR 4798624 Coil, A/C Evaporator (AN 1993-1995) AR 4723069 Coil, A/C Evaporator (AS 1992) AR 4734292 Coil, A/C Evaporator (AS 1993-1994) AR 4797131 Coil, A/C Evaporator (AS 1995) AR 4723518 Coil, A/C Evaporator (BR 1994) AR 4798705 Coil, A/C Evaporator (BR 1995) AR 4644790 Coil, A/C Evaporator (JA 1995) AR 4797129 Coil, A/C Evaporator (LH 1993-1995) AR 4797130 Coil, A/C Evaporator (PL 1995) AR 4723518 Coil, A/C Evaporator (ZJ 1993-1994) AR 4798705 Coil, A/C Evaporator (ZJ 1995) REPAIR PROCEDURE B - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1 4728942 A/C Evaporator Cleaner 1 4740319 Reusable Applicator 1 NPN Pair of Rubber Gloves 1 NPN Pair of Safety Glasses REPAIR PROCEDURE A: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 7091 This repair involves checking the A/C condensation drain tube for proper operation and replacing the A/C evaporator coil. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. 2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts and Equipment Required section. Follow all evaporator removal and replacement instructions listed in the appropriate vehicle Service Manual. REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper operation and cleaning and disinfecting the A/C evaporator coil and housing. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. NOTE: FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE WATER TO FLUSH EYES IF NECESSARY 2. Protect the interior of the vehicle with a drop cloth. 3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the evaporator coil. NOTE: FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM. 4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the dash panel). Open the vehicle doors. On AS Body models, remove the resistor block. NOTE: ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT. 6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319. 7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty. Spray into the resistor block opening on "AS" models. 8. Turn the vehicle OFF and allow to soak for at least 30 minutes. 9. Wipe off any excess cleaner from around the instrument panel ducts. 10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle for 20 minutes to dry the system. NOTE: FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE ODOR PROBLEM. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-95 Evaporator, Replace 1994 (AB) 2.7 Hrs. 1995 (AB) 1.9 Hrs. 1992-93 (AC/AY) 2.0 Hrs. 1993-95 (AN) 2.2 Hrs. 1992-93 (AS) 2.4 Hrs. 1994-95 (AS) 3.8 Hrs. 1994-95 (BR) 3.3 Hrs. **1995 (JA) 3.7 Hrs.** 1993 (LH) 4.1 Hrs. 1994-95 (LH) 3.4 Hrs. 1995 (PL) 3.9 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 7092 1993-95 (ZJ) 3.1 Hrs. Optional Equipment 24-65-02-60 Console Equipped 1992-93 (AS) 0.2 Hrs. 1993-95 (LH) 0.2 Hrs. 24-65-02-66 50/50 Bench Seat 1993-95 (LH) 0.8 Hrs. FAILURE CODE: P8 - New Part **24-65-02-94** Evaporator, Clean and Disinfect 0.7 Hrs. FAILURE CODE: YP - Odor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 241794 > Nov > 94 > A/C - Evaporator Freezes Up/Lack Of Cooling Evaporator Core: All Technical Service Bulletins A/C - Evaporator Freezes Up/Lack Of Cooling NO.: 24-17-94 GROUP: Heater & A/C DATE: Nov. 18, 1994 SUBJECT: A/C Evaporator Freeze-Up or Lack of Cooling on Cycling Clutch A/C Systems (Fixed Displacement Compressor) THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-17-92 DATED DEC. 14, 1992 WHICH SHOULD BE NOTED IN YOUR FILES. THE REVISION CONSISTS OF ADDITIONAL MODELS. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: DISCUSSION: A loss of A/C airflow and/or cooling while the A/C blower fan continues to operate may be experienced on some of the above vehicles. The electrical signal from the A/C cycling clutch switch passes through the Powertrain Control Module (PCM) to engage and disengage the A/C clutch relay. If the PCM is not properly disengaging the A/C clutch via the relay, the compressor will stay on continuously and result in evaporator freeze-up. Also, the PCM may not energize the A/C clutch relay at all. This condition results in the lack of cooling from the A/C system. The PCM should be checked per the procedure in the appropriate Powertrain Diagnostic Procedure Manual. Diagnostic Trouble Code 33 (A/C clutch relay circuit) will be present when either of these conditions are caused by the PCM. It is important to perform the complete test sequence because there are other A/C clutch relay circuit components that could also cause or contribute to the condition. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 241294 > Jul > 94 > A/C Evaporator - High Pitched Whistle Noise Evaporator Core: All Technical Service Bulletins A/C Evaporator - High Pitched Whistle Noise NO: 24-12-94 GROUP: Heater & A/C DATE: Jul. 8, 1994 SUBJECT: A/C Evaporator High Pitch Whistle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-30-93, DATED DEC. 3, 1993. THIS IS A COMPLETE REVISION, AND COPIES OF TECHNICAL SERVICE BULLETIN 24-30-93 IN YOUR FILES AND/OR THE 1993 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-94000), SHOULD BE NOTED TO REFER TO TECHNICAL SERVICE BULLETIN 24-12-94. MODELS: 1993 - 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH P/N 4677203 EXPANSION VALVES. THE PART NUMBER IS STAMPED ON THE EXPANSION VALVE NEXT TO THE LOW PRESSURE CUT-OUT SWITCH. A DIFFERENT TYPE OF EXPANSION VALVE HAS BEEN USED IN VEHICLE PRODUCTION SINCE APPROXIMATELY 11/93 FOR 2.5L ENGINE EQUIPPED VEHICLES, 3/94 FOR 3.3L AND 3.8L ENGINE EQUIPPED VEHICLES. THE DIFFERENT TYPE OF EXPANSION VALVE WILL BE USED AT THE START OF THE 1995 MODEL YEAR FOR 3.0L ENGINE EQUIPPED VEHICLES. SYMPTOM/CONDITION: Under certain conditions, the internal flow of R-134a refrigerant may set up a resonance in some evaporator cores. This resonance can emit from the dash area as a high-pitched whistle noise. The whistle noise usually lasts 3 to 5 seconds and starts shortly after the A/C compressor clutch engages. The duration and the intensity of the whistle noise may vary as well as be highly intermittent. The whistle noise is most likely to be experienced in ambient temperatures above 85 degrees Fahrenheit and engine speeds around 2000 RPM. DIAGNOSIS: Diagnosis may be very difficult due to the intermittent nature of the whistle condition. If ambient temperatures in excess of 85 degrees Fahrenheit are not present for test drive purposes, have the vehicle owner describe in detail the condition(s) in which they experience their concern to determine if this bulletin applies. PARTS REQUIRED: 1 4677334 Valve, A/C Expansion 1 4677045 Gasket, A/C Expansion Valve To Evaporator 1 3846834 Gasket, A/C Expansion Valve To Refrigerant Line REPAIR PROCEDURE: This bulletin involves installing a different type of expansion valve. 1. Recover the R-134a refrigerant while completely discharging the A/C system. WARNING: THE A/C SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS OPERATION. 2. Remove the boot-type wire connector from the low pressure cut-off switch. 3. Remove the 3-pin connector from the Electronic Cycling Clutch Switch (ECCS). 4. Remove the bolt in the center of the refrigerant line sealing plate. 5. Carefully pull the refrigerant line sealing plate from the expansion valve. 6. Cover the openings on refrigerant line sealing plate to prevent contamination. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 241294 > Jul > 94 > A/C Evaporator - High Pitched Whistle Noise > Page 7101 7. Remove the two screws attaching the expansion valve to the evaporator sealing plate. 8. Carefully remove the expansion valve and the two aluminum gaskets. 9. Place a new gasket (P/N 4677045) on the evaporator sealing plate. 10. Carefully hold the new expansion valve (P/N 4677334) to the evaporator sealing plate, DO NOT SCRATCH THE SEALING SURFACES. Install the two attaching screws and torque to 70 130 in.lbs. (8-14 N-m). 11. Place a new gasket (P/N 3846834) on the refrigerant line sealing plate. 12. Carefully hold the refrigerant line sealing plate to the expansion valve, DO NOT SCRATCH THE SEALING SURFACES. Install the attaching bolt and torque to 170 - 230 in.lbs. (20 - 26 N-m.). 13. Connect the wire connectors to the low pressure cut-off switch and the ECCS. 14. Evacuate and recharge the A/C system. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-35-20-90 0.8 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 242193 > Sep > 93 > AC Ducts - Emit Odors Evaporator Core: All Technical Service Bulletins AC Ducts - Emit Odors NO.: 24-21-93 GROUP: Air Conditioning DATE: Sep. 3, 1993 SUBJECT: Air Conditioning Ducts Emits Odor NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-12-92. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** MODELS: 1992**- 1993** (AC) Dynasty/New Yorker Salon (built after Jan. 31, 1992 - MDH 0131XX) 1992**- 1994** (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country 1992**- 1993** (AY) Imperial/New Yorker Fifth Avenue (built after Jan. 31, 1992 - MDH 0131XX) SYMPTOM/CONDITION: Some vehicles may emit an odor from the air conditioning ducts. The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related odors are possible, and are covered separately below: CAUSE AND CORRECTION - VEHICLES WITH LESS THAN 12,000 MILES **On some vehicles with the plate fin A/C evaporator, the manufacturing process occasionally results in an excessive amount of corrosion protection coating being applied on the evaporator external surfaces.** A heavy coating can result in an odor from the evaporator fins, especially when dry fins become wet from condensation. To correct this condition, the evaporator coil in the A/C unit must be replaced. Refer to the appropriate service manual for the replacement procedure. CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended use resulting from possible accumulation of foreign matter in the A/C unit. This condition is more likely to occur in vehicles that have been in extended use in humid climates. To correct this condition, the internal surfaces of the A/C air handling system will have to be cleaned by the repair procedure outlined in this bulletin. PARTS AND EQUIPMENT REQUIRED: VEHICLES WITH LESS THAN 12,000 MILES 1 Coil, A/C Evaporator AS 1992 4723069 AS 1993 - 1994 4474842 AC & AY 4677011 VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1 A/C Evaporator Cleaner 4728942 1 Reusable Applicator 4740319 1 Pair Of Rubber Gloves 1 Pair Of Safety Glasses REPAIR PROCEDURE: This bulletin involves cleaning and disinfecting the A/C evaporator and housing. NOTE: FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR CLEANER. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 242193 > Sep > 93 > AC Ducts - Emit Odors > Page 7106 - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE WATER TO FLUSH EYES IF NECESSARY 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Correct if necessary. 2. Protect the interior of the vehicle with a drop cloth. 3. Start the engine, set the blower on HIGH, air on recirculate, turn the A/C compressor OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the evaporator coil. 4. Switch to outside air. With a shop rag, block about 90% of the outside air inlet to increase air velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the dash panel). Open the vehicles doors. On "AS" Body models, remove the resistor block. **NOTE: THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING THE SCREWS COUNTER-CLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT.** 5. Shake the bottle of evaporator cleaner. Connect the bottle and a compressed air supply, with at least 80 PSI of pressure, to the reusable applicator. 6. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty. Spray into the resistor block opening on "AS" models. 7. Turn the vehicle OFF and allow to soak for at least 30 minutes. 8. Wipe off any excess cleaner from around the instrument panel ducts. 9. Start the engine, set the blower on HIGH, air on recirculate, **turn the A/C compressor OFF, open all of the instrument panel ducts, and open all of the vehicles windows.** Run the vehicle for 20 minutes to dry the system. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. Replace Evaporator AC & AY 1992 - 1993 24-65-90-91 2.0 Hrs. AS 1992 - 1994 24-65-90-91 2.4 Hrs. Clean Evaporator AC, AS & AY 24-65-90-90 0.3 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 241794 > Nov > 94 > A/C - Evaporator Freezes Up/Lack Of Cooling Evaporator Core: All Technical Service Bulletins A/C - Evaporator Freezes Up/Lack Of Cooling NO.: 24-17-94 GROUP: Heater & A/C DATE: Nov. 18, 1994 SUBJECT: A/C Evaporator Freeze-Up or Lack of Cooling on Cycling Clutch A/C Systems (Fixed Displacement Compressor) THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-17-92 DATED DEC. 14, 1992 WHICH SHOULD BE NOTED IN YOUR FILES. THE REVISION CONSISTS OF ADDITIONAL MODELS. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: DISCUSSION: A loss of A/C airflow and/or cooling while the A/C blower fan continues to operate may be experienced on some of the above vehicles. The electrical signal from the A/C cycling clutch switch passes through the Powertrain Control Module (PCM) to engage and disengage the A/C clutch relay. If the PCM is not properly disengaging the A/C clutch via the relay, the compressor will stay on continuously and result in evaporator freeze-up. Also, the PCM may not energize the A/C clutch relay at all. This condition results in the lack of cooling from the A/C system. The PCM should be checked per the procedure in the appropriate Powertrain Diagnostic Procedure Manual. Diagnostic Trouble Code 33 (A/C clutch relay circuit) will be present when either of these conditions are caused by the PCM. It is important to perform the complete test sequence because there are other A/C clutch relay circuit components that could also cause or contribute to the condition. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 7112 Evaporator Core: Specifications The oil designated for this vehicle is ND8 PAG (polyalkalene glycol). Front A/C - Evaporator 30 ml (1.0 oz) Dual A/C - Evaporator 60 ml (2.0 oz) - Rear Evap. 60 ml (2.0 oz) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement Evaporator Core: Service and Repair Evaporator Core Replacement NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. REMOVAL AND INSTALLATION WARNING: If equipped with air conditioning, the refrigeration system must be completely empty before proceeding. CAUTION: Disconnect battery negative cable, in engine compartment, before servicing instrument panel. 1. Set parking brake. 2. Disconnect battery negative cable. 3. Using a refrigerant recovery machine, remove refrigerant from the A/C system. 4. Disconnect all engine compartment lines and vacuum hoses. 5. Drain engine coolant. Plug coolant lines. INSTRUMENT PANEL CLUSTER BEZEL 1. To remove top cover use a flat blade tool. Pry up on either end and continue across the full length of the top cover. 2. To remove cluster bezel grille use the removal tool. Using tool at either end pull up and remove grille. 3. Remove six mounting screws from the hood and message center assembly. Using a flat blade tool pry up on either end and remove module and disconnect wire connector. 4. Reach behind lower right corner of center bezel and pull to disconnect attaching clip. Repeat in all of the corners and remove bezel. Disconnect ash receiver wire and lamp assembly if equipped. 5. Remove three instrument cluster bezel screws on the bottom of bezel and three at the upper left. Pulling up and rearward on the top edge of bezel remove bezel. 6. Disconnect POD switches wiring connectors. LOWER RIGHT INSTRUMENT PANEL Steering Column Cover 1. Remove steering column cover. 2. Remove premium console. 3. Remove center trim bezel. Remove ash receiver lamp and socket if equipped. 4. Remove A/C heater control. 5. Disconnect cigar lighter. 6. Remove screw in air duct. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement > Page 7115 Glove Box 7. Remove attaching screws and right lower panel. Screw location: - One screw outboard right of lower panel - Two screws in ash receiver/cupholder opening - Two screws bottom on the lower right - One screw in heater duct above heater control. - Remove glove box attaching screws and disconnect check straps. - Disconnect glove box lamp. INSTRUMENT PANEL REMOVAL WARNING: Chock wheels when instrument panel is to be rolled down. The steering column is removed and transmission may be out of park. Release the park brake before the release cable is disconnected. Disconnecting park brake cable while park brake is engaged may cause personal injury. Silencer Panel 1. Remove lower left instrument panel silencer. 2. Set parking brake and shift gear selector into low. 3. Remove lower left reinforcement. 4. Disconnect transmission range indicator at column. 5. Unhook transmission range indicator cable eyelet from column actuating arm: - Release column insert lock tab. - Squeeze legs together and lift insert from steering column, leave insert free. - Place cable on instrument panel to avoid transmission range indicator cable damage during removal. 6. Remove steering column.See: Steering and Suspension/Steering/Steering Column/Service and Repair 7. Remove lower right instrument panel silencer. 8. Remove floor braces. 9. Remove A-pillar intermediate and sill scuff garnish moldings. 10. Unfasten the hood release mechanism from the side cowl. 11. Disconnect the brake light switch, parking brake switch and bulk head wiring connectors. 12. Under the hood disconnect the ABS connector and resistor block. Unseat the grommet at the dash panel and feed wiring back into passenger compartment. 13. Remove the two nuts, securing the instrument panel, at the steering column support brace. 14. Loosen the instrument panel roll up bolts. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement > Page 7116 15. Remove the six screws securing the instrument panel at the fence line. 16. Roll the instrument panel back and hang it from the short position of the roll up hook. 17. With instrument panel hanging in the short position disconnect the left side body wiring connections. 18. Roll the instrument panel to the long position on the roll up hook and perform the following operations: - Disconnect the antenna cable. - Disconnect the blower motor lead connection. - Disconnect the temperature control cable from the A/C or heater unit. - Disconnect the vacuum lines from the climate control assembly - Disconnect the right side body wiring connectors. 19. Remove instrument panel from vehicle. 20. Disconnect the A/C unit hanger strap from the unit and temporarily reposition. 21. Remove the rubber condensate drain tube (in engine compartment). 22. Remove the four nuts (in the engine compartment) securing the unit to the dash panel. 23. Pull the entire unit rearward until the studs on the unit clear the dash panel. Drop the unit down. Pull it rearward to remove it from vehicle. DISASSEMBLY 1. Place heater A/C unit assembly on workbench. 2. Remove one screw at the vacuum harness. Feed harness through hole in cover. 3. Remove thirteen screws from top cover and remove cover. Temperature control door will come out with the cover. Remove the nut and lever from the door shaft to remove the temperature door from the cover. Heater Core 4. Remove screw from heater core tube retaining bracket and lift heater core out of unit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement > Page 7117 A/C Evaporator 5. Remove A/C evaporator coil out of unit. 6 Disconnect actuator linkage from fresh-recirculation door and vacuum lines from actuator. Loosen two nuts at actuator to housing and remove actuator. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement > Page 7118 7 Remove four screws at fresh-recirculation cover to unit and lift off cover. 8 Fresh/recirculating door may now be removed from its housing. 9 To remove heat defrost door, remove clip from shaft inside the housing. Pull shaft from housing and remove door. 10 To remove mode door, remove clip from shaft inside the housing. Pull the shaft from the housing and remove door. ASSEMBLY 1. Place evaporator coil into unit. 2. Place heater core into unit and fasten with screws. 3. Reinstall blower wheel onto blower motor shaft and secure with retaining clamp. 4. Feed blower motor wires through hole in housing. Lower blower assembly (rubber seal in place) into housing. Pull wiring grommet into place and install three mounting screws. 5. Install blower motor assembly (five screws) to housing. 6. Install fresh/recirculating door into housing. Install fresh/recirculating cover (four screws). Rotate actuator shaft into door and slide actuator into bracket and tighten two nuts. 7. To install mode door to housing, insert door shaft through housing and door pivot and demister spring. Push on shaft retainer 8. To install demister door, connect wire spring to demister door. Insert pivot end of door into hole in housing. Position opposite into slot. 9. To install heat/defrost door, insert door shaft through housing and door pivot. Push on shaft retainer. 10. Install heat distribution duct to bottom of housing with three screws. 11. To install temperature control door, install door shaft into lower pivot in the case housing. Place unit cover over housing while feeding temperature door shaft through cover. If the temperature control door is attached to the cover, feed the door into the housing with the cover. Direct the bottom pivot of the door with your hand through the mode door opening. 12. To install housing cover, line up cover to housing using pilot pins, the temperature door; and screw holes for alignment. Install thirteen screws. 13. Route vacuum harness through holes in cover. Install screw to retain vacuum harness. Make all vacuum hose attachments to vacuum actuators. NOTE: When installing cluster, do not kink or bind transmission range indicator guide tube and position guide tube in original location. Move shift lever to Neutral (N) and note pointer location. Move shift lever to D, L and P note pointer location. Adjust, if necessary to center pointer on N. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement > Page 7119 Evaporator Core: Service and Repair Rear Evaporator and Expansion Valve Replacement REMOVE NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. WARNING: On vehicles equipped with rear A/C, the refrigerant system must be emptied before performing the following operation. The engine cooling system must also be relieved of all pressure. Rear Heater Plumbing 1. Drain engine cooling system. Disconnect heater hoses at rear heater A/C unit. Rear A/C Plumbing 2. Using a refrigerant recovery machine, remove refrigerant from the A/C system. Disconnect A/C plumbing from rear heater A/C unit. 3. Remove left lower quarter trim panel. 4. Remove screws securing air distribution duct to the rear wheel housing. 5. Remove screws securing heater unit to the floor pan. 6. Remove screw securing unit to the quarter panel support. 7. Lift the unit enough to clear floor pan. Remove unit from the vehicle. EVAPORATOR AND EXPANSION VALVE 1. Remove unit cover. 2. Remove the bolt that mounts the unified refrigerant plumbing block to the expansion valve. 3. Carefully pull the evaporator and expansion valve straight out of unit. CAUTION: Do not scratch the sealing surfaces with the plumbing extension tube pilots. 4. Remove and discard the aluminum gasket between the plumbing extension and the expansion valve. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement > Page 7120 5. Cover the plumbing extension sealing surface to prevent contamination. 6. Bring evaporator and expansion valve to a clean work space. 7. Remove two 1/4-20 Torx Head screws. 8. Remove expansion valve. 9. Measure and record the amount of residual oil from the removed evaporator. INSTALL 1. Replace the aluminum gaskets. 2. Hold expansion valve against evaporator sealing plate CAUTION: Do not scratch the sealing surface. 3. Install two screws and tighten to 70 to 130 inch pounds (8 to 14 Nm). 4. Carefully install the evaporator and expansion valve straight into the unit. Do not scratch the sealing surfaces with the plumbing extension tube pilots. 5. Determine the amount of old refrigerant oil drained from the evaporator. Add this amount (of clean refrigerant oil) back into the system. 6. Carefully align the expansion valve onto the pilot tube of the plumbing sealing plate (do not scratch the sealing surface). Install the bolt through the plumbing plate into the unit sealing plate. Tighten bolts to 170 to 230 inch pounds (20 to 26 Nm). 7. Install unit cover and air distribution duct. 8. Install quarter trim panel, evacuate/charge system, and test performance. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor Evaporator Drain Tube: Customer Interest Air Conditioning Ducts - Emits Musty Odor NO: 24-06-95 Rev. A GROUP: Heater & A/C DATE: May 26, 1995 SUBJECT: Air Conditioning Ducts Emit Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 DATED MAY 5, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NUMBERS HAVE BEEN CORRECTED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1994 - 1995 (AB) Ram Van/Wagon (Built On or After Aug. 1, 1993 - MDH 08-01-XX) 1992 - 1993 (AC) Dynasty/New Yorker Salon (Built On or After Jan. 31, 1992 - MDH 01-31 -XX) 1993 - 1995 (AN) Dakota 1992 - 1995 (AS) Caravan/Voyager/Town & Country 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built On or After Jan. 31, 1992 - MDH 01-31-XX) 1994 - 1995 (BR) Ram Truck 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concord/Intrepid/LHS/New Yorker/Vision 1995 (PL) Neon 1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicles may emit a "musty" odor from the air conditioning ducts. The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related odors are possible, and are covered separately below: CAUSE AND CORRECTION - VEHICLES IN SERVICE LESS THAN 12 MONTHS On some vehicles with "plate fin" A/C evaporators, the manufacturing process occasionally results in an excessive amount of corrosion protection coating being applied on the evaporator external surfaces. A heavy coating can result in an odor from the evaporator fins, especially when dry fins become wet from condensation. A new coating has been developed to correct this condition. The evaporator coil in the A/C unit must be replaced. Proceed to Repair Procedure A. CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended use resulting from possible accumulation of "foreign matter" in the AC unit. This condition is more likely to occur in vehicles that have been in extended use in humid climates. To correct this condition, the internal surfaces of the A/C air handling system will have to be cleaned. Proceed to Repair Procedure B. PARTS AND EQUIPMENT REQUIRED: REPAIR PROCEDURE A - VEHICLES IN SERVICE LESS THAN 12 MONTHS AR 4798625 Coil, A/C Evaporator (AB 1994-1995, Vehicles Built On or After Aug. 1,1993) AR 4677011 Coil, A/C Evaporator (AC/AY 1992-1993, Vehicles Built On or After Jan. 31,1992) AR 4798624 Coil, A/C Evaporator (AN 1993-1995) AR 4723069 Coil, A/C Evaporator (AS 1992) AR 4734292 Coil, A/C Evaporator (AS 1993-1994) AR 4797131 Coil, A/C Evaporator (AS 1995) AR 4723518 Coil, A/C Evaporator (BR 1994) AR 4798705 Coil, A/C Evaporator (BR 1995) AR 4644790 Coil, A/C Evaporator (JA 1995) AR 4797129 Coil, A/C Evaporator (LH 1993-1995) AR 4797130 Coil, A/C Evaporator (PL 1995) AR 4723518 Coil, A/C Evaporator (ZJ 1993-1994) AR 4798705 Coil, A/C Evaporator (ZJ 1995) REPAIR PROCEDURE B - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1 4728942 A/C Evaporator Cleaner 1 4740319 Reusable Applicator 1 NPN Pair of Rubber Gloves 1 NPN Pair of Safety Glasses REPAIR PROCEDURE A: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 7129 This repair involves checking the A/C condensation drain tube for proper operation and replacing the A/C evaporator coil. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. 2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts and Equipment Required section. Follow all evaporator removal and replacement instructions listed in the appropriate vehicle Service Manual. REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper operation and cleaning and disinfecting the A/C evaporator coil and housing. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. NOTE: FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE WATER TO FLUSH EYES IF NECESSARY 2. Protect the interior of the vehicle with a drop cloth. 3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the evaporator coil. NOTE: FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM. 4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the dash panel). Open the vehicle doors. On AS Body models, remove the resistor block. NOTE: ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT. 6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319. 7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty. Spray into the resistor block opening on "AS" models. 8. Turn the vehicle OFF and allow to soak for at least 30 minutes. 9. Wipe off any excess cleaner from around the instrument panel ducts. 10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle for 20 minutes to dry the system. NOTE: FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE ODOR PROBLEM. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-95 Evaporator, Replace 1994 (AB) 2.7 Hrs. 1995 (AB) 1.9 Hrs. 1992-93 (AC/AY) 2.0 Hrs. 1993-95 (AN) 2.2 Hrs. 1992-93 (AS) 2.4 Hrs. 1994-95 (AS) 3.8 Hrs. 1994-95 (BR) 3.3 Hrs. **1995 (JA) 3.7 Hrs.** 1993 (LH) 4.1 Hrs. 1994-95 (LH) 3.4 Hrs. 1995 (PL) 3.9 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 7130 1993-95 (ZJ) 3.1 Hrs. Optional Equipment 24-65-02-60 Console Equipped 1992-93 (AS) 0.2 Hrs. 1993-95 (LH) 0.2 Hrs. 24-65-02-66 50/50 Bench Seat 1993-95 (LH) 0.8 Hrs. FAILURE CODE: P8 - New Part **24-65-02-94** Evaporator, Clean and Disinfect 0.7 Hrs. FAILURE CODE: YP - Odor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor Evaporator Drain Tube: All Technical Service Bulletins Air Conditioning Ducts - Emits Musty Odor NO: 24-06-95 Rev. A GROUP: Heater & A/C DATE: May 26, 1995 SUBJECT: Air Conditioning Ducts Emit Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 DATED MAY 5, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NUMBERS HAVE BEEN CORRECTED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1994 - 1995 (AB) Ram Van/Wagon (Built On or After Aug. 1, 1993 - MDH 08-01-XX) 1992 - 1993 (AC) Dynasty/New Yorker Salon (Built On or After Jan. 31, 1992 - MDH 01-31 -XX) 1993 - 1995 (AN) Dakota 1992 - 1995 (AS) Caravan/Voyager/Town & Country 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built On or After Jan. 31, 1992 - MDH 01-31-XX) 1994 - 1995 (BR) Ram Truck 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concord/Intrepid/LHS/New Yorker/Vision 1995 (PL) Neon 1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicles may emit a "musty" odor from the air conditioning ducts. The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related odors are possible, and are covered separately below: CAUSE AND CORRECTION - VEHICLES IN SERVICE LESS THAN 12 MONTHS On some vehicles with "plate fin" A/C evaporators, the manufacturing process occasionally results in an excessive amount of corrosion protection coating being applied on the evaporator external surfaces. A heavy coating can result in an odor from the evaporator fins, especially when dry fins become wet from condensation. A new coating has been developed to correct this condition. The evaporator coil in the A/C unit must be replaced. Proceed to Repair Procedure A. CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended use resulting from possible accumulation of "foreign matter" in the AC unit. This condition is more likely to occur in vehicles that have been in extended use in humid climates. To correct this condition, the internal surfaces of the A/C air handling system will have to be cleaned. Proceed to Repair Procedure B. PARTS AND EQUIPMENT REQUIRED: REPAIR PROCEDURE A - VEHICLES IN SERVICE LESS THAN 12 MONTHS AR 4798625 Coil, A/C Evaporator (AB 1994-1995, Vehicles Built On or After Aug. 1,1993) AR 4677011 Coil, A/C Evaporator (AC/AY 1992-1993, Vehicles Built On or After Jan. 31,1992) AR 4798624 Coil, A/C Evaporator (AN 1993-1995) AR 4723069 Coil, A/C Evaporator (AS 1992) AR 4734292 Coil, A/C Evaporator (AS 1993-1994) AR 4797131 Coil, A/C Evaporator (AS 1995) AR 4723518 Coil, A/C Evaporator (BR 1994) AR 4798705 Coil, A/C Evaporator (BR 1995) AR 4644790 Coil, A/C Evaporator (JA 1995) AR 4797129 Coil, A/C Evaporator (LH 1993-1995) AR 4797130 Coil, A/C Evaporator (PL 1995) AR 4723518 Coil, A/C Evaporator (ZJ 1993-1994) AR 4798705 Coil, A/C Evaporator (ZJ 1995) REPAIR PROCEDURE B - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1 4728942 A/C Evaporator Cleaner 1 4740319 Reusable Applicator 1 NPN Pair of Rubber Gloves 1 NPN Pair of Safety Glasses REPAIR PROCEDURE A: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 7136 This repair involves checking the A/C condensation drain tube for proper operation and replacing the A/C evaporator coil. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. 2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts and Equipment Required section. Follow all evaporator removal and replacement instructions listed in the appropriate vehicle Service Manual. REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper operation and cleaning and disinfecting the A/C evaporator coil and housing. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. NOTE: FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE WATER TO FLUSH EYES IF NECESSARY 2. Protect the interior of the vehicle with a drop cloth. 3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the evaporator coil. NOTE: FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM. 4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the dash panel). Open the vehicle doors. On AS Body models, remove the resistor block. NOTE: ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT. 6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319. 7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty. Spray into the resistor block opening on "AS" models. 8. Turn the vehicle OFF and allow to soak for at least 30 minutes. 9. Wipe off any excess cleaner from around the instrument panel ducts. 10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle for 20 minutes to dry the system. NOTE: FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE ODOR PROBLEM. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-95 Evaporator, Replace 1994 (AB) 2.7 Hrs. 1995 (AB) 1.9 Hrs. 1992-93 (AC/AY) 2.0 Hrs. 1993-95 (AN) 2.2 Hrs. 1992-93 (AS) 2.4 Hrs. 1994-95 (AS) 3.8 Hrs. 1994-95 (BR) 3.3 Hrs. **1995 (JA) 3.7 Hrs.** 1993 (LH) 4.1 Hrs. 1994-95 (LH) 3.4 Hrs. 1995 (PL) 3.9 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 7137 1993-95 (ZJ) 3.1 Hrs. Optional Equipment 24-65-02-60 Console Equipped 1992-93 (AS) 0.2 Hrs. 1993-95 (LH) 0.2 Hrs. 24-65-02-66 50/50 Bench Seat 1993-95 (LH) 0.8 Hrs. FAILURE CODE: P8 - New Part **24-65-02-94** Evaporator, Clean and Disinfect 0.7 Hrs. FAILURE CODE: YP - Odor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 241294 > Jul > 94 > A/C Evaporator - High Pitched Whistle Noise Expansion Valve: Customer Interest A/C Evaporator - High Pitched Whistle Noise NO: 24-12-94 GROUP: Heater & A/C DATE: Jul. 8, 1994 SUBJECT: A/C Evaporator High Pitch Whistle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-30-93, DATED DEC. 3, 1993. THIS IS A COMPLETE REVISION, AND COPIES OF TECHNICAL SERVICE BULLETIN 24-30-93 IN YOUR FILES AND/OR THE 1993 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-94000), SHOULD BE NOTED TO REFER TO TECHNICAL SERVICE BULLETIN 24-12-94. MODELS: 1993 - 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH P/N 4677203 EXPANSION VALVES. THE PART NUMBER IS STAMPED ON THE EXPANSION VALVE NEXT TO THE LOW PRESSURE CUT-OUT SWITCH. A DIFFERENT TYPE OF EXPANSION VALVE HAS BEEN USED IN VEHICLE PRODUCTION SINCE APPROXIMATELY 11/93 FOR 2.5L ENGINE EQUIPPED VEHICLES, 3/94 FOR 3.3L AND 3.8L ENGINE EQUIPPED VEHICLES. THE DIFFERENT TYPE OF EXPANSION VALVE WILL BE USED AT THE START OF THE 1995 MODEL YEAR FOR 3.0L ENGINE EQUIPPED VEHICLES. SYMPTOM/CONDITION: Under certain conditions, the internal flow of R-134a refrigerant may set up a resonance in some evaporator cores. This resonance can emit from the dash area as a high-pitched whistle noise. The whistle noise usually lasts 3 to 5 seconds and starts shortly after the A/C compressor clutch engages. The duration and the intensity of the whistle noise may vary as well as be highly intermittent. The whistle noise is most likely to be experienced in ambient temperatures above 85 degrees Fahrenheit and engine speeds around 2000 RPM. DIAGNOSIS: Diagnosis may be very difficult due to the intermittent nature of the whistle condition. If ambient temperatures in excess of 85 degrees Fahrenheit are not present for test drive purposes, have the vehicle owner describe in detail the condition(s) in which they experience their concern to determine if this bulletin applies. PARTS REQUIRED: 1 4677334 Valve, A/C Expansion 1 4677045 Gasket, A/C Expansion Valve To Evaporator 1 3846834 Gasket, A/C Expansion Valve To Refrigerant Line REPAIR PROCEDURE: This bulletin involves installing a different type of expansion valve. 1. Recover the R-134a refrigerant while completely discharging the A/C system. WARNING: THE A/C SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS OPERATION. 2. Remove the boot-type wire connector from the low pressure cut-off switch. 3. Remove the 3-pin connector from the Electronic Cycling Clutch Switch (ECCS). 4. Remove the bolt in the center of the refrigerant line sealing plate. 5. Carefully pull the refrigerant line sealing plate from the expansion valve. 6. Cover the openings on refrigerant line sealing plate to prevent contamination. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 241294 > Jul > 94 > A/C Evaporator - High Pitched Whistle Noise > Page 7146 7. Remove the two screws attaching the expansion valve to the evaporator sealing plate. 8. Carefully remove the expansion valve and the two aluminum gaskets. 9. Place a new gasket (P/N 4677045) on the evaporator sealing plate. 10. Carefully hold the new expansion valve (P/N 4677334) to the evaporator sealing plate, DO NOT SCRATCH THE SEALING SURFACES. Install the two attaching screws and torque to 70 130 in.lbs. (8-14 N-m). 11. Place a new gasket (P/N 3846834) on the refrigerant line sealing plate. 12. Carefully hold the refrigerant line sealing plate to the expansion valve, DO NOT SCRATCH THE SEALING SURFACES. Install the attaching bolt and torque to 170 - 230 in.lbs. (20 - 26 N-m.). 13. Connect the wire connectors to the low pressure cut-off switch and the ECCS. 14. Evacuate and recharge the A/C system. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-35-20-90 0.8 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 241294 > Jul > 94 > A/C Evaporator - High Pitched Whistle Noise Expansion Valve: All Technical Service Bulletins A/C Evaporator - High Pitched Whistle Noise NO: 24-12-94 GROUP: Heater & A/C DATE: Jul. 8, 1994 SUBJECT: A/C Evaporator High Pitch Whistle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-30-93, DATED DEC. 3, 1993. THIS IS A COMPLETE REVISION, AND COPIES OF TECHNICAL SERVICE BULLETIN 24-30-93 IN YOUR FILES AND/OR THE 1993 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-94000), SHOULD BE NOTED TO REFER TO TECHNICAL SERVICE BULLETIN 24-12-94. MODELS: 1993 - 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH P/N 4677203 EXPANSION VALVES. THE PART NUMBER IS STAMPED ON THE EXPANSION VALVE NEXT TO THE LOW PRESSURE CUT-OUT SWITCH. A DIFFERENT TYPE OF EXPANSION VALVE HAS BEEN USED IN VEHICLE PRODUCTION SINCE APPROXIMATELY 11/93 FOR 2.5L ENGINE EQUIPPED VEHICLES, 3/94 FOR 3.3L AND 3.8L ENGINE EQUIPPED VEHICLES. THE DIFFERENT TYPE OF EXPANSION VALVE WILL BE USED AT THE START OF THE 1995 MODEL YEAR FOR 3.0L ENGINE EQUIPPED VEHICLES. SYMPTOM/CONDITION: Under certain conditions, the internal flow of R-134a refrigerant may set up a resonance in some evaporator cores. This resonance can emit from the dash area as a high-pitched whistle noise. The whistle noise usually lasts 3 to 5 seconds and starts shortly after the A/C compressor clutch engages. The duration and the intensity of the whistle noise may vary as well as be highly intermittent. The whistle noise is most likely to be experienced in ambient temperatures above 85 degrees Fahrenheit and engine speeds around 2000 RPM. DIAGNOSIS: Diagnosis may be very difficult due to the intermittent nature of the whistle condition. If ambient temperatures in excess of 85 degrees Fahrenheit are not present for test drive purposes, have the vehicle owner describe in detail the condition(s) in which they experience their concern to determine if this bulletin applies. PARTS REQUIRED: 1 4677334 Valve, A/C Expansion 1 4677045 Gasket, A/C Expansion Valve To Evaporator 1 3846834 Gasket, A/C Expansion Valve To Refrigerant Line REPAIR PROCEDURE: This bulletin involves installing a different type of expansion valve. 1. Recover the R-134a refrigerant while completely discharging the A/C system. WARNING: THE A/C SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS OPERATION. 2. Remove the boot-type wire connector from the low pressure cut-off switch. 3. Remove the 3-pin connector from the Electronic Cycling Clutch Switch (ECCS). 4. Remove the bolt in the center of the refrigerant line sealing plate. 5. Carefully pull the refrigerant line sealing plate from the expansion valve. 6. Cover the openings on refrigerant line sealing plate to prevent contamination. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 241294 > Jul > 94 > A/C Evaporator - High Pitched Whistle Noise > Page 7152 7. Remove the two screws attaching the expansion valve to the evaporator sealing plate. 8. Carefully remove the expansion valve and the two aluminum gaskets. 9. Place a new gasket (P/N 4677045) on the evaporator sealing plate. 10. Carefully hold the new expansion valve (P/N 4677334) to the evaporator sealing plate, DO NOT SCRATCH THE SEALING SURFACES. Install the two attaching screws and torque to 70 130 in.lbs. (8-14 N-m). 11. Place a new gasket (P/N 3846834) on the refrigerant line sealing plate. 12. Carefully hold the refrigerant line sealing plate to the expansion valve, DO NOT SCRATCH THE SEALING SURFACES. Install the attaching bolt and torque to 170 - 230 in.lbs. (20 - 26 N-m.). 13. Connect the wire connectors to the low pressure cut-off switch and the ECCS. 14. Evacuate and recharge the A/C system. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-35-20-90 0.8 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 7153 Expansion Valve: Service and Repair REMOVE NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. WARNING: On vehicles equipped with rear A/C, the refrigerant system must be emptied before performing the following operation. The engine cooling system must also be relieved of all pressure. Rear Heater Plumbing 1. Drain engine cooling system. Disconnect heater hoses at rear heater A/C unit. Rear A/C Plumbing 2. Using a refrigerant recovery machine, remove refrigerant from the A/C system. Disconnect A/C plumbing from rear heater A/C unit. 3. Remove left lower quarter trim panel. 4. Remove screws securing air distribution duct to the rear wheel housing. 5. Remove screws securing heater unit to the floor pan. 6. Remove screw securing unit to the quarter panel support. 7. Lift the unit enough to clear floor pan. Remove unit from the vehicle. EVAPORATOR AND EXPANSION VALVE 1. Remove unit cover. 2. Remove the bolt that mounts the unified refrigerant plumbing block to the expansion valve. 3. Carefully pull the evaporator and expansion valve straight out of unit. CAUTION: Do not scratch the sealing surfaces with the plumbing extension tube pilots. 4. Remove and discard the aluminum gasket between the plumbing extension and the expansion valve. 5. Cover the plumbing extension sealing surface to prevent contamination. 6. Bring evaporator and expansion valve to a clean work space. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 7154 7. Remove two 1/4-20 Torx Head screws. 8. Remove expansion valve. 9. Measure and record the amount of residual oil from the removed evaporator. INSTALL 1. Replace the aluminum gaskets. 2. Hold expansion valve against evaporator sealing plate CAUTION: Do not scratch the sealing surface. 3. Install two screws and tighten to 70 to 130 inch pounds (8 to 14 Nm). 4. Carefully install the evaporator and expansion valve straight into the unit. Do not scratch the sealing surfaces with the plumbing extension tube pilots. 5. Determine the amount of old refrigerant oil drained from the evaporator. Add this amount (of clean refrigerant oil) back into the system. 6. Carefully align the expansion valve onto the pilot tube of the plumbing sealing plate (do not scratch the sealing surface). Install the bolt through the plumbing plate into the unit sealing plate. Tighten bolts to 170 to 230 inch pounds (20 to 26 Nm). 7. Install unit cover and air distribution duct. 8. Install quarter trim panel, evacuate/charge system, and test performance. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core Heater Core: Service and Repair Front Heater Core 1. Set parking brake and disconnect battery ground cable. 2. Discharge and recover system refrigerant. 3. Disconnect all engine compartment heater and air conditioning lines and vacuum hoses. 4. Drain engine coolant and plug lines. 5. Remove instrument panel as described in Instrument Panel/Service and Repair/Dash Panel Replacement. 6. Disconnect air conditioning hanger strap and temporarily reposition. 7. Remove rubber condensate drain tube and four mounting nuts in engine compartment. Fig. 10 A/C & Heater Assembly 8. Pull heater/air conditioning assembly to rear until unit studs clear dash panel, then drop unit down and remove from vehicle. 9. Place heater/air conditioning assembly on suitable workbench, then remove screw at vacuum harness and feed harness through hole in cover. 10. Remove thirteen screws from top cover, then remove top cover. 11. Remove screw from heater core tube retaining bracket, then lift heater core out of unit. 12. Remove evaporator core from unit. 13. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core > Page 7159 Heater Core: Service and Repair Rear Heater Core REMOVE AND INSTALL 1. Drain the engine coolant system. Rear Heater Plumbing 2. Disconnect heater tubing from the underbody heater lines to the rear unit. 3. Remove the lower left quarter trim panel. 4. Remove fan A/C distribution duct. 5. Remove heater-unit cover. 6. Carefully pull the heater core and heater tubes straight out of the unit. 7. Raise the heater core to drain residual coolant from the core. 8. Disconnect two heater hose clamps that attach plumbing to the heater core tube. 9. To install, reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hoses Heater Hose: Service and Repair Heater Hoses Review Safety Precautions and Warnings the in General Information section before proceeding with this operation. 1. Drain engine cooling system. 2. Loosen clamps at each end of heater hose to be removed. CAUTION: When removing hoses from heater core inlet or outlet nipples, do not use excessive force. Heater core may become damaged and leak engine coolant. 3. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the hose will not come off, slice the hose at the connector nipple and peal off heater hose. This method will require heater hose replacement. To install, reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hoses > Page 7165 Heater Hose: Service and Repair Underbody Plumbing WARNING: THE ENGINE COOLING SYSTEM MUST BE RELIEVED OF ALL PRESSURE. 1. Drain the engine cooling system. 2. In the engine compartment, and disconnect two auxiliary rear heater hoses from the (front) heater hose tee fittings. 3. Hoist the vehicle. Disconnect two push-together couplings from the auxiliary rear heater core tubes protruding through the floor pan. 4. Remove four bolts and one pal nut holding the plumbing to the floor pan and lower the plumbing from the vehicle. To Install, Reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > A/C Hose - Squeaking Noise Hose/Line HVAC: Technical Service Bulletins A/C Hose - Squeaking Noise NO: 24-02-94 GROUP: Heat & A/C DATE: Jan. 14, 1994 SUBJECT: Squeak in Right Shock Tower Area MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: If a squeaking noise seems to be coming from the right shock tower, a possible cause is the right shock tower A/C hose support bracket. This should be checked prior to looking elsewhere on or in the shock tower. If the insulation foam between the bracket and hoses is mis-positioned or worn through, a squeak may occur under driving conditions. Inspect the hose and bracket area and relocate or replace the foam or bend the bracket to eliminate any metal-to-metal contact. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 7170 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Removal and Installation Hose/Line HVAC: Service and Repair Removal and Installation REMOVAL (1) Recover A/C system. (2) Remove upper generator bracket. See: Starting and Charging/Charging System. (3) Remove ground wire at cowl. (4) Remove expansion valve plate and bolt (Fig.50. (5) Remove liquid line from expansion valve. (6) Remove wire connector at pressure transducer. (7) Remove liquid line mounting bracket at right frame rail. (8) Using access slot between radiator crossmember arid grille, loosen liquid line mounting plate at filter-drier. Remove liquid line from filter-drier. It may be necessary to bend liquid line in half to remove line. The replacement Tine is a two-piece assembly. INSTALLATION (1) To install, reverse preceding operation. Replace all O-rings. Install two-piece line in place of original part. Assemble line halves after it is installed on vehicle. (2) Evacuate and recharge A/C system. SUCTION LINE REMOVAL (1) Recover A/C system. (2) Remove suction line mounting nut at compressor (Fig. 51). (3) Remove upper generator bracket. See: Starting and Charging/Charging System (4) Remove ground wire at cowl. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Removal and Installation > Page 7173 (5) Remove expansion valve line plate nut (Fig.52). (6) Remove suction line mounting bracket. (7) Remove suction line. INSTALLATION (1) To install, reverse preceding operation. Replace all 0-rings. (2) Evacuate and recharge A/C system. DISCHARGE LINE REMOVAL (1) Recover A/C system (2) Remove discharge line mounting nut at compressor (Fig. 53). (3) Remove discharge line at the top fitting on the condenser (Fig. 54). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Removal and Installation > Page 7174 INSTALLATION (1) To install, reverse preceding operation. Replace all 0-rings. (2) Evacuate and recharge A/C system. (3) Perform HVAC Control calibration and test procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Removal and Installation > Page 7175 Hose/Line HVAC: Service and Repair Rear Air Conditioning Lines REMOVAL WARNING: THE REFRIGERANT SYSTEM MUST BE EMPTY BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Hoist the vehicle. Disconnect two tube-fittings from the engine compartment plumbing. 2. Remove the bolt from the unified plumbing block (left side of car, outboard of rail, forward of fuel tank). 3. Carefully pull refrigerant line assembly down (take care NOT to scratch the sealing surface with the tube pilots). Remove and discard the aluminum gasket and cover unit sealing surface to prevent contamination. 4. Remove two screws holding plumbing to the fuel tank support and left-side support rail (near muffler support bracket). 5. Remove two screws holding the plumbing to the floor pan. 6. Disconnect the parking brake system at hook above muffler and the cable connection near the support rails. 7. Fish the nylon tubing and unified plumbing block above the muffler support member. 8. Lower the plumbing from the vehicle. 9. Measure the residual oil in the under body plumbing out of each end of the plumbing. The lowside (larger diameter line) has a check valve that can restrict oil flow from the tube-fitting to the unified plumbing end of the hose. Measure clean R134a PAG refrigerant oil to be returned to the refrigerant system. INSTALL 1. Protect the plumbing ends from scratches. If plumbing is new, do not remove the shipping caps until joining together. 2. Reverse the preceding steps from the REMOVAL procedure. 3. New gaskets and O-rings are required for installation. The O-rings must be covered with clean refrigerant oil prior to installation. 4. Connect the tube-fittings to the engine compartment under body plumbing. Avoid misalignment of the threads (cross threading) and tighten to 200 in-lbs 5. Remove the shipping cap from the plumbing side sealing surface and verify that the aluminum gasket is present. 6. Carefully align the pilot tubes of the plumbing line block into the unit (take care not to scratch the sealing surface). 7. Install the bolt through the plumbing plate into the unit sealing plate. Tighten bolt to 200 +/- 30 in lbs (23 +/- 3 Nm). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair Housing Assembly HVAC: Service and Repair REMOVE AND INSTALL WARNING: On vehicles equipped with rear A/C, the refrigerant system must be discharged before performing the following operation. The engine cooling system must also be relieved of all pressure. Rear Heater Plumbing Rear A/C Plumbing 1. Drain engine cooling system. Disconnect heater hoses at rear heater-A/C unit. 2. Discharge refrigerant system. Disconnect A/C plumbing from rear heater-A/C unit. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 7179 Rear Heater-A/C Components 3. Remove left lower quarter trim panel. 4. Remove the attaching screws securing the air distribution duct to the rear wheel housing. 5. Remove the attaching screws securing the heater unit to the floor pan. 6. Remove attaching screw securing the unit to the quarter panel support. 7. Lift the unit enough to clear the floor pan and remove the unit from the vehicle. To Install, Reverse the preceding operation. Install new gaskets at refrigerant lines and expansion valve. Evacuate and charge the refrigerant system. Refill the cooling system. Test for leaks and overall performance. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications Receiver Dryer: Specifications The oil designated for this vehicle is ND8 PAG (polyalkalene glycol). Front A/C - Filter-Drier 15 ml (0.5 oz) Dual A/C - Filter-Drier 30 ml (1.0 oz) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > R 134A Refrigerant - Leak Detection Systems Refrigerant: Technical Service Bulletins R 134A Refrigerant - Leak Detection Systems NO.: 24-20-93 GROUP: Air Conditioning DATE: Jul. 30, 1993 SUBJECT: R-134A Refrigerant Leak Detection MODELS: DISCUSSION: Numerous R-134A leak detection units are on the market. Some units are better than others, and keep in mind R-134A is more difficult to detect than R-12 because of R-134A's smaller molecular structure. Listed below are the R-134A leak detection units currently approved by Chrysler: HITECH Instruments models HI 300 TEL, HI 350, HI 400 NOVA TEL, and HI 450 NOVA. Leybold Inficon models HLD4000 and D/TEC. OTC/Yokogawa model H10N. All Jeep/Eagle dealers were shipped R-134A equipment in March 1992 to be able to service the ZJ products and Chrysler/Plymouth/Dodge dealers were shipped the same equipment in May 1993. A HITECH Instruments, Model HI 300 TEL leak detector, was included in these equipment packages. Use of any other R-134A leak detection equipment will lead to improper diagnosis, repeat repairs and customer dissatisfaction. HITECH Instruments Models are available through Professional Service Equipment. Points to keep in mind when performing R-134A leak detection: * Testing should be performed 5-7 minutes after A/C system has be turned off. * The hood should be raised at least 5 minutes prior to performing leak detection. This is to help ensure any accumulation of R-134A can dissipate and prevent detecting false leaks throughout the engine compartment. * The probe should be moved at a rate of 1-2 inches per second and no more than 1/2 inch from the surface being checked. DO NOT HOLD THE PROBE IN ONE LOCATION OR ALLOW THE PROBE TO TOUCH ANY SURFACE OR LIQUID. Doing so may contaminate the probe and cause false readings. * Probe along the bottom side of the components because R-134A is heavier than air. * Leak detector probes are very sensitive to contaminants. Do not expose probes to lubricants, paint, welding and mastic fumes, vehicle fuel, exhaust or coolant, halogenated solvents, chlorinated water or steam, dust, powder, or direct streams of R-12 or R-134A. Contaminants cause false readings. * Always follow the leak detector manufacturer's instructions very closely. * A properly maintained and calibrated APPROVED LEAK DETECTOR is your best tool for accurate leak detection and customer satisfaction. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > R 134A Refrigerant - Leak Detection Systems > Page 7187 Refrigerant: Technical Service Bulletins R 134A Refrigerant - Leak Detection NO.: 24-13-94 GROUP: Air Conditioning DATE: Sep. 9, 1994 SUBJECT: R-134a Refrigerant Leak Detection MODELS: 1994 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1994 - 1995 (AB) Ram Van/Ram Wagon 1994 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1994 - 1995 (AN) Dakota/Dakota Cab & Chassis 1994 (AP) Shadow/Sundance 1993 - 1995 (AS) Caravan/Voyager/Town & Country 1994 (BD) Laser/Talon (Midyear Change) 1994 - 1995 (BR) Ram Truck 1994 - 1995 (B7) Stealth 1994 - 1995 (B8) Colt Vista/Summit Wagon 1994 - 1995 (B9) Colt/Summit 1994 - 1995 (ES) Chrysler Voyager (Export Only) 1995 (FJ) Avenger/Sebring/Talon 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1995 (PL) Neon 1993 - 1995 (SR) Viper 1994 - 1995 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: R-134a refrigerant leaks are more difficult to detect than R-12 because of the smaller molecular structure. Listed below are the R-134a leak detection units currently approved by Chrysler and SAE: HITECH Instruments Models HI 300 TEL, H1350, HI 400 NOVA TEL, and Hi 450 NOVA Leybold Inficon Models HLD4000 and D/TEC OTC/Yokogawa Model H10N NOTE: LEAK DETECTOR PROBES ARE VERY SENSITIVE TO CONTAMINANTS. DO NOT EXPOSE PROBES TO LUBRICANTS, PAINT, WELDING AND MASTIC FUMES, VEHICLE FUEL, EXHAUST OR COOLANT, HALOGENATED SOLVENTS, CHLORINATED WATER OR STEAM, DUST, POWDER, OR DIRECT STREAMS OF R-12 OR R134a. ANY TIME CONTAMINATION IS VISUALLY PRESENT ON THE PROBE, OR THE PROBE IS SUSPECTED OF BEING NEAR A CONTAMINANT, FOLLOW THE MANUFACTURERS RECOMMENDATION FOR CLEANING OR REPLACING THE FILTER/SENSOR. ONLY A PROPERLY MAINTAINED LEAK DETECTOR WILL PROVIDE ACCURATE LEAK DETECTION. TECHNICIAN PROCEDURE FOR USING ELECTRONIC REFRIGERANT LEAK DETECTORS FOR SERVICE OF MOBILE AIR CONDITIONING SYSTEMS SAE Recommended Practice J1628 1. The electronic leak detector shall be operated in accordance with the equipment manufacturer's operating instructions. 2. Leak test with the engine not in operation. 3. The air conditioning system shall be charged with sufficient refrigerant to have a gauge pressure of at least 340 kPa (50 psi) when not in operation. At temperatures below 15~C (59~F), leaks may not be measurable since this pressure may not be reached. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > R 134A Refrigerant - Leak Detection Systems > Page 7188 4. Take care not to contaminate the detector probe if the part being tested is contaminated. If the part is particularly dirty, it should be wiped off with a dry shop towel or blown off with shop air. No cleaners or solvents shall be used, since many electronic detectors are sensitive to their ingredients. 5. Visually trace the entire refrigerant system and look for signs of air conditioning lubricant leakage, damage, or corrosion on all lines, hoses, and components. Each questionable area should be carefully checked with the detector probe, as well as all fittings, hose to line couplings, refrigerant controls, service ports with caps off, brazed or welded areas, and areas around attachment points and holddowns on lines and components. 6. Always follow the refrigerant system around in a continuous path so that no areas of potential leaks are missed. If a leak is found, always continue to test the remainder of the system. 7. At each area checked, the probe should be moved around at a rate of no more than 25 to 50 mm/s (1 to 2 inches/second), and no more than 5 mm (1/4 in.) from the surface completely around the position. Slower and closer movement of the probe greatly improves the likelihood of finding a leak. 8. An apparent leak should be verified at least once by blowing shop air into the area of the suspected leak, if necessary, and repeating the check of the area. In cases of very large leaks, blowing out the area with shop air often helps locate the exact position of a leak. 9. Leak testing of the evaporator core while in the air conditioning module should be accomplished by turning the air conditioning blower on high for a period of 15 seconds minimum, shutting it off, then waiting for the refrigerant to accumulate in the case for time specified by 9.1, then inserting the leak detector probe into the condensate drain hole if no water is present, or into the closest opening in the heating/ventilation/air conditioning case to the evaporator, such as heat duct or vent duct. If the detector alarms, a leak apparently has been found. NOTE: R134a REFRIGERANT IS HEAVIER THAN AIR AND WILL TEND TO STAY LOW IN THE A/C MODULE. 9.1 The accumulation time shall be specified by the leak detector manufacturer in the instructions included with the detector, or a minimum of 2 minutes. 10. Following any service to the refrigerant system of the vehicle, and any other service which disturbs the refrigerant system, a leak test of the repair and of the service ports of the refrigerant system should be done. NOTE: CURRENTLY THERE IS NO CHRYSLER APPROVED R-134A REFRIGERANT LEAK DETECTION DYE AVAILABLE. USE OF AN UNAPPROVED DYE WILL CAUSE DAMAGE TO THE A/C SYSTEM. AN APPROVED DYE WILL BE AVAILABLE IN THE NEAR FUTURE. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications A/C System With Rear AC ....................................................................................................................................... ....................................................... 1.420 kg (50 oz) Without Rear AC .................................................................................................................................. ...................................................... 1.020 kg (36 oz) Capacities Capacities Capacity 2.25 lb (US) Capacities Capacities Capacity 3.25 lb (US) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 7191 Refrigerant: Fluid Type Specifications A/C Refrigerant Specifications A/C Refrigerant Specifications Refrigerant type R134a Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Specifications Refrigerant Filter: Specifications The oil designated for this vehicle is ND8 PAG (polyalkalene glycol). Front A/C - Filter-Drier 15 ml (0.5 oz) Dual A/C - Filter-Drier 30 ml (1.0 oz) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications A/C System When all air conditioning system is first assembled, all components (except the compressor) are refrigerant oil free. After the system has been charged with R134a refrigerant and operated, the oil in the compressor is dispersed through the lines and components. The evaporator, condenser, and filter-drier will retain a significant amount of oil, see below. When a component is replaced, the specified amount of refrigerant oil must be added. When the compressor is replaced, the amount of oil that is retained in the rest of the system must be drained from the replacement compressor. When a line or component has ruptured and oil has escaped, the compressor should be removed and drained. The filter-drier must be replaced along with the ruptured part. The oil capacity of the system, minus the amount of oil still in the remaining components, can be measured and poured into the suction port of the compressor. EXAMPLE: On a dual system the evaporator retains 60 ml (2 oz). The condenser retains 30 ml (1 oz) of oil, and system capacity may be 220 ml (7.40 oz) of oil. 220 ml minus 90 ml = 130 ml (4.40 oz). CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were designed to work with R-134a refrigerant. The oil designated for this vehicle is ND-8 PAG (polyalkalene glycol). Front A/C - Compressor ....................................................................................................................................... ................................................. 142 ml (4.73 oz) - Filter-Drier ......................................................................................................................................... ................................................... 15 ml (0.5 oz) - Condenser ......................................................................................................................................... ..................................................... 15 ml (0.5 oz) - Evaporator ......................................................................................................................................... .................................................... 30 ml (1.0 oz) Dual A/C - Compressor ....................................................................................................................................... ................................................... 220 ml (7.4 oz) - Filter-Drier ......................................................................................................................................... ................................................... 30 ml (1.0 oz) - Condenser ......................................................................................................................................... ..................................................... 30 ml (1.0 oz) - Evaporator ......................................................................................................................................... .................................................... 60 ml (2.0 oz) - Rear Evaporator ................................................................................................................................ ..................................................... 60 ml (2.0 oz) Capacities Capacities Ounces Viscosity 4.73 oz (US) ND8 PAG Polyalkaline Glycol Capacities Capacities Ounces Viscosity 7.40 oz (US) ND8 PAG Polyalkaline Glycol Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 7199 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, Polyalkylene Glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to an R-134a refrigerant system. Refrigerant oil will absorb any moisture it comes in contact with, including moisture in the air. The oil container should be kept tightly capped until it is ready to be used. Then, cap the oil immediately after using, to prevent contamination. There are different PAG oils available, and each contains a different additive package. The refrigerant oil designated for this vehicle is ND-8 PAG . Use only refrigerant oil of this same type to service the refrigerant system. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair > Oil Charge Additions Refrigerant Oil: Service and Repair Oil Charge Additions It will not be necessary to check the oil level in the compressor or add oil unless there has been an oil loss. Oil loss at the leak point will be evident by the presence of a wet, shiny surface around the leak. If a leak is detected and the compressor must be removed, it is not necessary to discharge the system unless the refrigerant lines will be removed for service. If the lines will be removed, discharge system as outlined in "System Diagnosis/Evacuating the A/C System" and note the following procedure: 1. Disconnect battery ground cable. 2. Loosen and remove drive belts and disconnect compressor clutch wire lead. 3. Remove refrigerant lines from compressor. 4. Remove compressor attaching nuts and bolts. 5. From suction port on top of compressor, drain refrigerant oil from compressor. 6. Install replacement components. 7. Add system capacity minus the capacity of components that have not been replaced. 8. Reverse procedure to install. 9. Evacuate and recharge system. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair > Oil Charge Additions > Page 7202 Refrigerant Oil: Service and Repair Purging Compressor The compressor must be purged of air whenever it has been isolated from the system for service. 1. Install oil plugs or reconnect refrigerant lines and manual valves to compressor as needed. 2. Cap service access ports on both manual valves, then rotate low (suction) side service valve counterclockwise to the back-seated position. 3. Rotate high (discharge) side manual valve to mid-position, then slightly loosen cap on high side gauge port to allow refrigerant to force air out of compressor. 4. Back seat high side manual valve, then tighten gauge port cap. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations Engine Compartment Wiring Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Low Pressure Cut-Off Switch Low Pressure Sensor / Switch: Locations Low Pressure Cut-Off Switch The Low pressure cut-out switch (LPCO) is located on the expansion valve. The expansion valve is silver in color. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Low Pressure Cut-Off Switch > Page 7211 Low Pressure Sensor / Switch: Locations Low Pressure Cycling Clutch Switch The Electronic Cycling Clutch Switch (ECCS) is located on the A/C expansion valve at the rear of engine compartment. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7212 Low Pressure Sensor / Switch: Description and Operation The Low Pressure Cut-Off (LPCO) Switch monitors the refrigerant gas pressure on the suction side of. the system. The LPCO is located on the expansion valve, and the expansion valve is silver in color. The LPCO turns off voltage to the compressor clutch coil when refrigerant gas pressure drops to levels that could damage the compressor. The LPCO is a sealed factory calibrated unit. It must be replaced if defective. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7213 Low Pressure Sensor / Switch: Testing and Inspection Low Pressure Cut-off Switch The work area temperature must not be below 10°C (50°F) to test the compressor clutch. circuit 1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Raise hood and disconnect LPCO switch connector boot. 3. Using a suitable jumper wire, jump across the terminals inside wire connector boot. 4. If the compressor clutch does not engage, the cycling clutch switch, wiring, relay, or fuse can be defective. 5. If clutch engages, connect manifold gauge set. Read low pressure gauge. At pressure above 97 kPa (14 psi) and above, LPCO switch will complete the clutch circuit. If the low pressure gauge reads below 172 kPa (25 psi), the system is low on refrigerant charge or empty due to a leak. 6. Install connector boot on switch and repeat step number 3. If the clutch does not engage, replace the. LPCO switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Low Pressure Cut-Out Switch Replacement Low Pressure Sensor / Switch: Service and Repair Low Pressure Cut-Out Switch Replacement Low Pressure Cut-Off Switch (LPCO) REMOVAL AND INSTALLATION WARNING: The refrigeration system must be completely empty before proceeding with this operation. 1. Disconnect the boot like wire connector at the cut-off switch. 2. Using a sender unit type socket, remove the switch from the expansion valve. To insure an adequate seal on the switch, use a small amount of thread sealing tape. Reverse the preceding steps. Evacuate and charge the system. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Low Pressure Cut-Out Switch Replacement > Page 7216 Low Pressure Sensor / Switch: Service and Repair Low Pressure Cycling Clutch Switch Replacement Electronic Cycling Clutch Switch Combo Valve (ECCS) REMOVAL AND INSTALLATION 1. Disconnect the 3 pin connector at the ECCS. 2. Remove 4 mm hex bolt from side of expansion valve. 3. Slip the capillary tube from the well on the expansion valve. The capillary-tube-well is filled with a special temperature conductive grease. Save this special grease and reuse it when installing the new switch. To install, reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation Blower Motor Relay: Description and Operation Chrysler does not use a Blower Motor Relay for these Year/Make/Model Vehicles. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 7224 In Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 7225 Compressor Clutch Relay: Description and Operation Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 7226 In Power Distribution Center PURPOSE Supplies ground path for A/C compressor clutch. OPERATION Controlled by A/C or defrost switch (inside vehicle) and Powertrain Control Module (PCM). Relay receives battery voltage from radiator fan relay , (A/C relay will not energize unless the radiator fan relay is energized). When A/C or defrost is selected, (turned ON), inside vehicle, and low and high pressure switches are closed, PCM receives an A/C ON signal. PCM then supplies relay ground. If PCM senses Wide Open Throttle (WOT) or low idle speed condition, it removes relay ground, discontinueing A/C clutch engagement. PCM delays activation of A/C relay for a specific period after engine start-up. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Engine Compartment Components RH Side Of Engine Compartment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Locations Air Conditioning Switch: Locations Heater A/C Controls Center Of I/P Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Front End Components Front Of Engine Compartment, Front Of Radiator Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations Engine Compartment Wiring Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Low Pressure Cut-Off Switch Low Pressure Sensor / Switch: Locations Low Pressure Cut-Off Switch The Low pressure cut-out switch (LPCO) is located on the expansion valve. The expansion valve is silver in color. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Low Pressure Cut-Off Switch > Page 7248 Low Pressure Sensor / Switch: Locations Low Pressure Cycling Clutch Switch The Electronic Cycling Clutch Switch (ECCS) is located on the A/C expansion valve at the rear of engine compartment. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7249 Low Pressure Sensor / Switch: Description and Operation The Low Pressure Cut-Off (LPCO) Switch monitors the refrigerant gas pressure on the suction side of. the system. The LPCO is located on the expansion valve, and the expansion valve is silver in color. The LPCO turns off voltage to the compressor clutch coil when refrigerant gas pressure drops to levels that could damage the compressor. The LPCO is a sealed factory calibrated unit. It must be replaced if defective. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7250 Low Pressure Sensor / Switch: Testing and Inspection Low Pressure Cut-off Switch The work area temperature must not be below 10°C (50°F) to test the compressor clutch. circuit 1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Raise hood and disconnect LPCO switch connector boot. 3. Using a suitable jumper wire, jump across the terminals inside wire connector boot. 4. If the compressor clutch does not engage, the cycling clutch switch, wiring, relay, or fuse can be defective. 5. If clutch engages, connect manifold gauge set. Read low pressure gauge. At pressure above 97 kPa (14 psi) and above, LPCO switch will complete the clutch circuit. If the low pressure gauge reads below 172 kPa (25 psi), the system is low on refrigerant charge or empty due to a leak. 6. Install connector boot on switch and repeat step number 3. If the clutch does not engage, replace the. LPCO switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Low Pressure Cut-Out Switch Replacement Low Pressure Sensor / Switch: Service and Repair Low Pressure Cut-Out Switch Replacement Low Pressure Cut-Off Switch (LPCO) REMOVAL AND INSTALLATION WARNING: The refrigeration system must be completely empty before proceeding with this operation. 1. Disconnect the boot like wire connector at the cut-off switch. 2. Using a sender unit type socket, remove the switch from the expansion valve. To insure an adequate seal on the switch, use a small amount of thread sealing tape. Reverse the preceding steps. Evacuate and charge the system. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Low Pressure Cut-Out Switch Replacement > Page 7253 Low Pressure Sensor / Switch: Service and Repair Low Pressure Cycling Clutch Switch Replacement Electronic Cycling Clutch Switch Combo Valve (ECCS) REMOVAL AND INSTALLATION 1. Disconnect the 3 pin connector at the ECCS. 2. Remove 4 mm hex bolt from side of expansion valve. 3. Slip the capillary tube from the well on the expansion valve. The capillary-tube-well is filled with a special temperature conductive grease. Save this special grease and reuse it when installing the new switch. To install, reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations Discharge Valve Service Port Suction Valve Service Port Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Heating and Air Conditioning > System Relay, HVAC > Component Information > Locations Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least ten minutes after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 7266 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming ARMING 1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate SRS system is functioning correctly. 5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air Bag Systems/Testing and Inspection. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment Technical Service Bulletin # 818 Date: 990701 Recall - Inadvertent Airbag Deployment July 1999 Dealer Service Instructions for: Safety Recall No. 818 Airbag System Wiring Models 1994 - 1995 (AS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth Voyager/Grand Voyager IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service as determined by using the DIAL VIP System. Subject The wiring that initiates the driver and/or passenger airbags on about 935,000 of the above vehicles may electrically short circuit to ground. A short circuit to ground that exists immediately after turning the ignition key to the "ON" or "START" position can cause the airbag(s) to inadvertently deply. Inadvertent airbag deployment can injure a front seat occupant. Repair A mastic patch must be installed on every vehicle. In addition, a diagnostic test of the airbag system must be performed. Shorted initiator (squib) wiring must be repaired (which may involve replacing the clockspring). If the rear wiper motor must be replace. Alternate Transportation If inspection determines that clockspring and/or rear wiper motor replacement is required and the vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7275 Use one of the table labor operation numbers and time allowances shown. Add the cost of the parts used plus applicable dealer allowance to your claim. Use the labor operation number and time allowance shown if an owner requires replacement of a rear wiper motor at some time in the future after the recall has already been completed. Parts Return If a REMANUFACTURED rear wiper motor was ordered: Removed rear wiper motors must be returned for core credit as quickly as possible using the Mopar Core Return Procedure on your DIAL terminal. You can access the procedure from Option 4 on the Parts System menu, then select Function 10. If a NEW rear wiper motor was ordered: Removed rear wiper motors must be returned to the Warranty Material Return Center. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing and material return instructions. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7276 DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD818". Owner Notification and Service Scheduling Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7277 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7278 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Provided with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Parts Information A. Mastic Patch Part Number Description 55275444AB Mastic Patch Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Mastic Patches to service about 25% of those vehicles. B. Clockspring Assembly Package Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7279 Part Number Description CCXR8181 Clockspring with Speed Control CCLR8182 Clockspring without Speed Control Each package contains a clockspring and a mastic patch. Due to the small number of involved vehicles expected to require clockspring replacement, each dealer will receive one clockspring for vehicles equipped with speed control. No clockspring assemblies for vehicles without speed control will be distributed initially. Additional clockspring packages should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require clockspring replacement. C. Tie Strap/Clips and Heat Shrink Tubing In addition, each dealer will receive one package often (10) tie strap/clips (P/N 05016944AA) and ten (10) pieces of heat shrink tubing (P/N 04778570) to repair damaged wiring if necessary. Additional tie strap/clips and heat shrink tubing may be ordered as necessary. D. Rear Wiper Motor Assembly Part Number Description R4673326 Remanufactured Rear Wiper Motor Assembly OR 04673326 New Rear Wiper Motor Assembly Due to the small number of involved vehicles expected to require rear wiper motor replacement, no wiper motors will be distributed initially. Wiper motors should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require rear wiper motor replacement. A. Install Mastic Patch & Check For Airbag System Diagnostic Trouble Codes (DTC's): 1. Turn on the rear wiper motor and allow it to run for several cycles, then turn it off. 2. Remove the five (5) steering column cover attaching screws and lower the cover (Figure 1). 3. Disconnect the liftgate release switch electrical connector (Figure 1). 4. Disconnect the parking hand brake linkage. 5. Set the lower steering column cover aside. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7280 6. Install the provided mastic patch on the right edge of the fuse/relay/kneeblocker bracket (Figure 2). 7. Insert the Super Card 2 into the DRB III(R) (Scan Tool) and then using cable CH7020, connect the DRB III to the underdash diagnostic connector (blue connector to the right of the steering column) and power it up. 8. Use the arrow keys and select # 1 - DRB III STAND ALONE on the DRB III MAIN MENU Screen. 9. Turn the ignition key tot he "ON" position. 10. Use the arrow keys and select # 1 - 1983-1997 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU Screen. 11. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the SUPERCARD MAIN MENU Screen. 12. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU Screen. 13. Use the arrow keys and select # 6 - PASSIVE RESTRAINTS on the SELECT SYSTEM Screen. 14. Use the arrow keys and select # 1 - AIRBAG on the SELECT RESTRAINT SYSTEM Screen. 15. Use the arrow keys and select # 2 - READ DTC'S on the SELECT FUNCTION Screen. 16. Use the arrow keys and select # 1 - ACTIVE on the DTC TYPE Screen. 17. Record all active DTC's for future reference. 18. Press the PAGE BACK key to return to the DTC TYPE Screen. 19. Use the arrow keys and select # 2- STORED on the DTC TYPE Screen. 20. Record all stored DTC's for future reference. 21. Press the PAGE BACK key to continue. 22. Use the arrow keys and select ERASE DTC'S on the DTC Screen (if DTC'S were present). 23. Press the PAGE BACK key to continue. 24. Turn the ignition key off and disconnect the DRB III. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7281 25. If the airbag system has one or more of the three DTC's in the table, proceed as shown in the table. If no airbag system DTC's exist, continue with Step 26. NOTE: Refer to the appropriate Diagnostic Manual for the proper diagnostic and repair procedures on any airbag system diagnostic trouble codes other than those listed above. 26. Install the lower steering column cover (Figure 1). 27. Connect the parking hand brake linkage. 28. Connect the liftgate release switch electrical connector (Figure 1). 29. Tighten the lower steering column cover screws securely. 30. Return the vehicle to the customer. No further action is necessary. B. Replace Rear Wiper Motor IMPORTANT: This section is only for vehicles with a "Loss of Ignition Run Only" diagnostic trouble code. 1. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the liftgate wiper arm assembly. 3. Open and raise the liftgate. 4. Remove the two (2) speaker grille/courtesy lamp assemblies (Figure 3). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7282 5. Remove the plugs at the ends of the assist handle and remove the handle attaching screws (Figure 3). 6. Remove the two (2) plugs at the lower corners of the trim panel and remove the lower trim panel screws (Figure 3). 7. Remove the two (2) trim panel screws located in the speaker grille openings (Figure 3). 8. Remove the two (2) plugs near the speaker grille openings in the center of the trim panel and remove the screws (Figure 3). 9. Remove the six (6) trim panel screws along the top edge and upper sides of the trim panel (Figure 3). 10. Disengage the frog leg clips around the perimeter of the trim panel and remove the trim panel from the liftgate. 11. Disconnect the wiper motor electrical connector (Figure 4). 12. Remove the five (5) wiper motor bracket mounting screws (Figure 4). Remove the wiper motor and bracket assembly from the liftgate and set it aside. 13. Install the remanufactured or new rear wiper motor and bracket assembly into the liftgate. Torque the five (5) attaching screws to 35 in-lbs (4 Nm). 14. Connect the wiper motor electrical connector. 15. Position the liftgate trim panel on the liftgate and engage the frog-leg clips around the perimeter of the panel. 16. Install the six (6) screws along the top and upper sides of the trim panel (Figure 3). CAUTION: DO NOT over tighten screws as this could damage the trim panel or strip the screws. 17. Install the two (2) screws located in the speaker grille openings (Figure 3). 18. Install the two (2) screws and plugs in the center of the trim panel (Figure 3). 19. Install the two (2) screws and plugs in the lower trim panel comers (Figure 3). 20. Install the assist handle with the two (2) screws (Figure 3). Install the handle screw plugs. 21. Connect the courtesy lamp electrical connectors and install the speaker grille/courtesy lamp assemblies. 22. Close the liftgate. 23. Install the liftgate wiper arm assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7283 24. In the fuse block located under the instrument panel, replace the rear wiper motor/airbag fuse (Fuse # 13) with a new 20 amp fuse (Figure 5). 25. ^ If any other airbag system diagnostic trouble codes were detected and must be still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 26. 26. Install the lower steering column cover (Figure 1). 27. Connect the parking hand brake linkage. 28. Connect the liftgate release switch electrical connector (Figure 1). 29. Tighten the lower steering column cover screws securely. 30. Turn the ignition switch to the ON position and exit the vehicle. 31. Connect the negative battery terminal. 32. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 33. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. C. Repair Driver Airbag Wiring and.or Replace Clockspring IMPORTANT: This section is only for vehicles with a "Driver Squib Term Shorted to Ground" diagnostic trouble code. 1. Place the steering wheel in the straight ahead position. 2. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 3. Remove the upper and lower steering column shrouds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7284 4. Inspect the clockspring wiring pigtail routed along the steering column for cuts or chafing (Figure 6). ^ If NO cuts or chafing of the clockspring pigtail is found, continue with Step 5. ^ If cuts or chafing of the clockspring pigtail is found, but no wire strands have been damaged, repair the clockspring wires by taping the damaged area with high quality electrical tape and tie strap as shown in Figure 6. ^ If cuts or chafing of the clockspring pigtail is found and internal wire strands have been damaged, replace the clockspring assembly as follows: a. Remove the four (4) airbag module retaining nuts from the back side of the steering wheel, disconnect the airbag module electrical connector and then remove the airbag module from the steering wheel and set it aside (inflator side down/face up for safety). b. Disconnect the speed control switch connector (if equipped). c. Disconnect the horn connector. d. Remove the steering wheel retaining nut and then using a steering wheel puller (Special Tool C-3428B), remove the steering wheel. e. Disconnect the clockspring wiring connector near the top of the fuse block and unclip the wiring pigtail from the steering column. f. Disconnect the clockspring wiring connector from the back of the clockspring. g. Unclip the clockspring assembly locating fingers from the steering column and then remove and discard the clockspring. h. Snap the new clockspring onto the steering column. i. Route the clockspring pigtail down the steering column such that the section of the I/P wiring harness that connects to the ignition switch is between the pigtail and the steering column. Secure the clockspring pigtail to the I/P wiring harness with a tie strap (P/N 05016944AA) (Figure 6). j. Connect the clockspring pigtail to the I/P wiring harness connector. Secure the clockspring pigtail to the I/P wiring harness near the fuse/relay/kneeblocker bracket with a tie strap (P/N 05016944AA) (Figure 6). k. Install the steering wheel. Torque the steering wheel retaining nut to 45 ft-lbs (61 Nm). l. Connect the horn connector. m. Connect the speed control switch connector (if equipped). n. Connect the airbag module electrical connector and install the airbag module onto the steering wheel. Torque the airbag module retaining nuts to 90 in-lbs (10 Nm). 5. Install the upper and lower steering column shrouds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7285 6. Inspect the I/P wiring harness where it is routed past the brake pedal support to verify that the harness tie strap/clip is secured into the hole (Figure 7). ^ If the tie strap/clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 05016944AA) and insert the clip into the hole. 7. Install another mastic patch on the edge of the brake pedal support bracket to prevent damage to the I/P wiring harness as it routes up past the fuse block (Figure 7). 8. Remove the relay access cover. 9. Inspect the I/P wiring harness and verify that the harness tie strap/clip has been inserted into the tab off of the fuse/relay/kneeblocker bracket (Figure 8). ^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 0516944AA) and insert the clip into the hole. 10. Install another mastic patch to the outboard end of the steel tube that routes the transmission shifter cable and the steering column support bracket closest to the I/P wiring harness (Figure 8). 11. Install the relay access cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7286 12. Install the lower steering column cover (Figure 1). 13. Connect the liftgate release switch electrical connector (Figure 1). 14. Connect the liftgate release switch electrical connector (Figure 1). 15. Tighten the lower instruments panel cover screws securely. 16. Remove the two (2) screws that attach the lower console to the instrument panel support brackets (Figure 9). 17. Slide the cupholder out. 18. Remove the two (2) upper console attaching screws behind the cupholder (Figure 9). 19. Slide the console rearward and up to remove. 20. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM) (Figure 10). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7287 21. Install another mastic patch over the rear corner and left edge of the Body Control Module (BCM) (Figure 10). 22. Install the console assembly. 23. Install the upper console attaching screws behind the cupholder. Tighten the screws securely. Close the cupholder. 24. Install the two (2) lower console attaching screws (Figure 9). Tighten the screws securely. 25. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 26. 26. Turn the ignition switch to the ON position and exit the vehicle. 27. Connect the negative battery terminal. 28. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 29. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. D. Repair Passenger Airbag Wiring IMPORTANT: This section is only for vehicles with a "Passenger Squib Term Shorted to Ground" diagnostic trouble code. 1. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the two (2) screws that attach the lower console to the instrument panel support brackets (Figure 11). 3. Slide the cupholder out. 4. Remove the two (2) upper console attaching screws behind the cupholder (Figure 11). 5. Slide the console rearward and up to remove. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7288 6. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM) (Figure 12). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. 7. Install a mastic patch over the rear corner and left edge of the Body Control Module (BCM) (Figure 12). 8. Inspect the I/P wiring harness above the AECM and the BCM. Verify that the clip on the harness is installed into the hole on the back side of the left center console bracket (Figure 12). ^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the clip is missing or is damaged, install a new tie strap/clip (P/N 05016944AA) and insert the clip into the hole. 9. Install the console assembly. 10. Install the upper console attaching screws behind the cupholder. Tighten the screws securely (Figure 11). Close the cupholder. 11. Install the two (2) lower console attaching screws (Figure 11). Tighten the screws securely. 12. Disconnect the glove box door check straps and allow the door to open fully. 13. Working through the glove box opening, remove the four (4) screws that attach the passenger airbag module to the I/P bracket (Figure 13). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7289 14. Using a large flat-tipped screwdriver, pry the module up to unsnap the door from the trim pad and lift it away from the snaps (Figure 14). 15. Hold the passenger airbag module door and raise the module from the opening. DO NOT disconnect the airbag module electrical connectors. 16. Inspect the I/P wiring harness just behind the passenger airbag connectors (Figure 15). Any chafed or cut wires should be repaired per the Wiring Repair. 17. Install a mastic patch on the edge of the passenger airbag module near the electrical connectors (Figure 15). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7290 18. Inspect the passenger airbag module takeout on the I/P wiring harness near the vertical support bracket attached to the lip support tube (Figure 16). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. 19. Install a mastic patch on the bottom edge of the support bracket just below the existing plastic edge cover (Figure 16). 20. Install the passenger airbag module into the I/P. Tighten the module attaching screws to 50 in-lbs (6 Nm) 21. Connect the glove box door check straps and then close the glove box door. 22. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 23. 23. Install the lower steering column cover (Figure 1). 24. Connect the parking hand brake linkage (Figure 1). 25. Connect the liftgate release switch electrical connector (Figure 1). 26. Tighten the lower steering column cover screws securely. 27. Turn the ignition switch to the ON position and exit the vehicle. 28. Connect the negative battery terminal. 29. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 30. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Wiring Repair Procedure IMPORTANT: If airbag system wiring is found chafed or damaged, the wiring should be repaired using the procedure listed below. ^ If the plastic wire covering is chafed but the wiring strands are NOT damaged: Tape the damaged area with high quality electrical tape. ^ If the plastic wire covering is chafed and the wiring strands are damaged: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7291 1. Cut the damaged wire in two. 2. Strip 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing, P/N 04778570, on one end of the wire. 4. Spread the strands of the wire apart on both of the exposed wire ends. 5. Push the two wire ends together until the strands of the wire are close to the insulation. 6. Twist the wires together. 7. Solder the connection together using rosin core solder. 8. Center the heat shrink tubing over the repair area and apply heat with a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out both ends of the tubing. 9. Secure the wire to the harness to prevent chafing or damage to the insulation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > NHTSA99V113000 > May > 99 > Recall 99V113000: Inadvertent Air Bag Deployment Air Bag: Recalls Recall 99V113000: Inadvertent Air Bag Deployment The wiring that initiates the driver and/or passenger air bag could electrically short circuit to ground. A short circuit to ground that exists immediately after turning the ignition key to the "ON" or "START" position can cause the air bag(s) to inadvertently deploy. Inadvertent air bag deployment can injure a front seat occupant. Dealers will perform an electronic diagnostic check. Any short circuits identified in either the driver's or passenger side air bag initiator wire circuit will be repaired. Owner notification began August 2, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 085993 > Nov > 93 > Instrument Panel - Squeak/Rattle From Right Side Air Bag: Customer Interest Instrument Panel - Squeak/Rattle From Right Side NO.: 08-59-93 GROUP: Electrical DATE: Nov. 19, 1993 SUBJECT: Right Side Instrument Panel Squeak/Rattle Noise MODELS: 1994 (AS) Caravan/Voyager/Town & Country SYMPTOM/CONDITION: A squeak or rattle may be heard coming from the right side of the Instrument Panel (IP) when driving on rough road surfaces. DIAGNOSIS: Visually inspect the position of the Passenger Air Bag (PAB) in the opening of the IP. If the PAB is not centered and/or flush with the surface of the IP, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves repositioning the PAB in the IP opening. 1. Disconnect the negative battery cable. 2. Disengage the two glove box door check straps to allow for access to the four PAB attaching screws. 3. Loosen the four black PAB attaching screws facing the glove box door until the PAB can be easily moved in the IP opening. 4. Center the PAB in the IP opening. Use firm hand pressure to push down on the PAB door to ensure the PAB maintains the centered position and is held flush to under-flush with the IP surface while tightening the four PAB attaching screws to 50 In.Lbs. (5.7 N-m). 5. Reattach the two glove box door check straps. 6. Reconnect the negative battery cable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 23-11-50-90 0.2 Hrs. FAILURE CODE: 51 - Improperly Installed Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service Air Bag: All Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 7306 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment Technical Service Bulletin # 818 Date: 990701 Recall - Inadvertent Airbag Deployment July 1999 Dealer Service Instructions for: Safety Recall No. 818 Airbag System Wiring Models 1994 - 1995 (AS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth Voyager/Grand Voyager IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service as determined by using the DIAL VIP System. Subject The wiring that initiates the driver and/or passenger airbags on about 935,000 of the above vehicles may electrically short circuit to ground. A short circuit to ground that exists immediately after turning the ignition key to the "ON" or "START" position can cause the airbag(s) to inadvertently deply. Inadvertent airbag deployment can injure a front seat occupant. Repair A mastic patch must be installed on every vehicle. In addition, a diagnostic test of the airbag system must be performed. Shorted initiator (squib) wiring must be repaired (which may involve replacing the clockspring). If the rear wiper motor must be replace. Alternate Transportation If inspection determines that clockspring and/or rear wiper motor replacement is required and the vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7311 Use one of the table labor operation numbers and time allowances shown. Add the cost of the parts used plus applicable dealer allowance to your claim. Use the labor operation number and time allowance shown if an owner requires replacement of a rear wiper motor at some time in the future after the recall has already been completed. Parts Return If a REMANUFACTURED rear wiper motor was ordered: Removed rear wiper motors must be returned for core credit as quickly as possible using the Mopar Core Return Procedure on your DIAL terminal. You can access the procedure from Option 4 on the Parts System menu, then select Function 10. If a NEW rear wiper motor was ordered: Removed rear wiper motors must be returned to the Warranty Material Return Center. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing and material return instructions. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7312 DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD818". Owner Notification and Service Scheduling Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7313 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7314 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Provided with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Parts Information A. Mastic Patch Part Number Description 55275444AB Mastic Patch Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Mastic Patches to service about 25% of those vehicles. B. Clockspring Assembly Package Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7315 Part Number Description CCXR8181 Clockspring with Speed Control CCLR8182 Clockspring without Speed Control Each package contains a clockspring and a mastic patch. Due to the small number of involved vehicles expected to require clockspring replacement, each dealer will receive one clockspring for vehicles equipped with speed control. No clockspring assemblies for vehicles without speed control will be distributed initially. Additional clockspring packages should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require clockspring replacement. C. Tie Strap/Clips and Heat Shrink Tubing In addition, each dealer will receive one package often (10) tie strap/clips (P/N 05016944AA) and ten (10) pieces of heat shrink tubing (P/N 04778570) to repair damaged wiring if necessary. Additional tie strap/clips and heat shrink tubing may be ordered as necessary. D. Rear Wiper Motor Assembly Part Number Description R4673326 Remanufactured Rear Wiper Motor Assembly OR 04673326 New Rear Wiper Motor Assembly Due to the small number of involved vehicles expected to require rear wiper motor replacement, no wiper motors will be distributed initially. Wiper motors should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require rear wiper motor replacement. A. Install Mastic Patch & Check For Airbag System Diagnostic Trouble Codes (DTC's): 1. Turn on the rear wiper motor and allow it to run for several cycles, then turn it off. 2. Remove the five (5) steering column cover attaching screws and lower the cover (Figure 1). 3. Disconnect the liftgate release switch electrical connector (Figure 1). 4. Disconnect the parking hand brake linkage. 5. Set the lower steering column cover aside. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7316 6. Install the provided mastic patch on the right edge of the fuse/relay/kneeblocker bracket (Figure 2). 7. Insert the Super Card 2 into the DRB III(R) (Scan Tool) and then using cable CH7020, connect the DRB III to the underdash diagnostic connector (blue connector to the right of the steering column) and power it up. 8. Use the arrow keys and select # 1 - DRB III STAND ALONE on the DRB III MAIN MENU Screen. 9. Turn the ignition key tot he "ON" position. 10. Use the arrow keys and select # 1 - 1983-1997 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU Screen. 11. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the SUPERCARD MAIN MENU Screen. 12. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU Screen. 13. Use the arrow keys and select # 6 - PASSIVE RESTRAINTS on the SELECT SYSTEM Screen. 14. Use the arrow keys and select # 1 - AIRBAG on the SELECT RESTRAINT SYSTEM Screen. 15. Use the arrow keys and select # 2 - READ DTC'S on the SELECT FUNCTION Screen. 16. Use the arrow keys and select # 1 - ACTIVE on the DTC TYPE Screen. 17. Record all active DTC's for future reference. 18. Press the PAGE BACK key to return to the DTC TYPE Screen. 19. Use the arrow keys and select # 2- STORED on the DTC TYPE Screen. 20. Record all stored DTC's for future reference. 21. Press the PAGE BACK key to continue. 22. Use the arrow keys and select ERASE DTC'S on the DTC Screen (if DTC'S were present). 23. Press the PAGE BACK key to continue. 24. Turn the ignition key off and disconnect the DRB III. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7317 25. If the airbag system has one or more of the three DTC's in the table, proceed as shown in the table. If no airbag system DTC's exist, continue with Step 26. NOTE: Refer to the appropriate Diagnostic Manual for the proper diagnostic and repair procedures on any airbag system diagnostic trouble codes other than those listed above. 26. Install the lower steering column cover (Figure 1). 27. Connect the parking hand brake linkage. 28. Connect the liftgate release switch electrical connector (Figure 1). 29. Tighten the lower steering column cover screws securely. 30. Return the vehicle to the customer. No further action is necessary. B. Replace Rear Wiper Motor IMPORTANT: This section is only for vehicles with a "Loss of Ignition Run Only" diagnostic trouble code. 1. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the liftgate wiper arm assembly. 3. Open and raise the liftgate. 4. Remove the two (2) speaker grille/courtesy lamp assemblies (Figure 3). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7318 5. Remove the plugs at the ends of the assist handle and remove the handle attaching screws (Figure 3). 6. Remove the two (2) plugs at the lower corners of the trim panel and remove the lower trim panel screws (Figure 3). 7. Remove the two (2) trim panel screws located in the speaker grille openings (Figure 3). 8. Remove the two (2) plugs near the speaker grille openings in the center of the trim panel and remove the screws (Figure 3). 9. Remove the six (6) trim panel screws along the top edge and upper sides of the trim panel (Figure 3). 10. Disengage the frog leg clips around the perimeter of the trim panel and remove the trim panel from the liftgate. 11. Disconnect the wiper motor electrical connector (Figure 4). 12. Remove the five (5) wiper motor bracket mounting screws (Figure 4). Remove the wiper motor and bracket assembly from the liftgate and set it aside. 13. Install the remanufactured or new rear wiper motor and bracket assembly into the liftgate. Torque the five (5) attaching screws to 35 in-lbs (4 Nm). 14. Connect the wiper motor electrical connector. 15. Position the liftgate trim panel on the liftgate and engage the frog-leg clips around the perimeter of the panel. 16. Install the six (6) screws along the top and upper sides of the trim panel (Figure 3). CAUTION: DO NOT over tighten screws as this could damage the trim panel or strip the screws. 17. Install the two (2) screws located in the speaker grille openings (Figure 3). 18. Install the two (2) screws and plugs in the center of the trim panel (Figure 3). 19. Install the two (2) screws and plugs in the lower trim panel comers (Figure 3). 20. Install the assist handle with the two (2) screws (Figure 3). Install the handle screw plugs. 21. Connect the courtesy lamp electrical connectors and install the speaker grille/courtesy lamp assemblies. 22. Close the liftgate. 23. Install the liftgate wiper arm assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7319 24. In the fuse block located under the instrument panel, replace the rear wiper motor/airbag fuse (Fuse # 13) with a new 20 amp fuse (Figure 5). 25. ^ If any other airbag system diagnostic trouble codes were detected and must be still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 26. 26. Install the lower steering column cover (Figure 1). 27. Connect the parking hand brake linkage. 28. Connect the liftgate release switch electrical connector (Figure 1). 29. Tighten the lower steering column cover screws securely. 30. Turn the ignition switch to the ON position and exit the vehicle. 31. Connect the negative battery terminal. 32. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 33. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. C. Repair Driver Airbag Wiring and.or Replace Clockspring IMPORTANT: This section is only for vehicles with a "Driver Squib Term Shorted to Ground" diagnostic trouble code. 1. Place the steering wheel in the straight ahead position. 2. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 3. Remove the upper and lower steering column shrouds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7320 4. Inspect the clockspring wiring pigtail routed along the steering column for cuts or chafing (Figure 6). ^ If NO cuts or chafing of the clockspring pigtail is found, continue with Step 5. ^ If cuts or chafing of the clockspring pigtail is found, but no wire strands have been damaged, repair the clockspring wires by taping the damaged area with high quality electrical tape and tie strap as shown in Figure 6. ^ If cuts or chafing of the clockspring pigtail is found and internal wire strands have been damaged, replace the clockspring assembly as follows: a. Remove the four (4) airbag module retaining nuts from the back side of the steering wheel, disconnect the airbag module electrical connector and then remove the airbag module from the steering wheel and set it aside (inflator side down/face up for safety). b. Disconnect the speed control switch connector (if equipped). c. Disconnect the horn connector. d. Remove the steering wheel retaining nut and then using a steering wheel puller (Special Tool C-3428B), remove the steering wheel. e. Disconnect the clockspring wiring connector near the top of the fuse block and unclip the wiring pigtail from the steering column. f. Disconnect the clockspring wiring connector from the back of the clockspring. g. Unclip the clockspring assembly locating fingers from the steering column and then remove and discard the clockspring. h. Snap the new clockspring onto the steering column. i. Route the clockspring pigtail down the steering column such that the section of the I/P wiring harness that connects to the ignition switch is between the pigtail and the steering column. Secure the clockspring pigtail to the I/P wiring harness with a tie strap (P/N 05016944AA) (Figure 6). j. Connect the clockspring pigtail to the I/P wiring harness connector. Secure the clockspring pigtail to the I/P wiring harness near the fuse/relay/kneeblocker bracket with a tie strap (P/N 05016944AA) (Figure 6). k. Install the steering wheel. Torque the steering wheel retaining nut to 45 ft-lbs (61 Nm). l. Connect the horn connector. m. Connect the speed control switch connector (if equipped). n. Connect the airbag module electrical connector and install the airbag module onto the steering wheel. Torque the airbag module retaining nuts to 90 in-lbs (10 Nm). 5. Install the upper and lower steering column shrouds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7321 6. Inspect the I/P wiring harness where it is routed past the brake pedal support to verify that the harness tie strap/clip is secured into the hole (Figure 7). ^ If the tie strap/clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 05016944AA) and insert the clip into the hole. 7. Install another mastic patch on the edge of the brake pedal support bracket to prevent damage to the I/P wiring harness as it routes up past the fuse block (Figure 7). 8. Remove the relay access cover. 9. Inspect the I/P wiring harness and verify that the harness tie strap/clip has been inserted into the tab off of the fuse/relay/kneeblocker bracket (Figure 8). ^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 0516944AA) and insert the clip into the hole. 10. Install another mastic patch to the outboard end of the steel tube that routes the transmission shifter cable and the steering column support bracket closest to the I/P wiring harness (Figure 8). 11. Install the relay access cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7322 12. Install the lower steering column cover (Figure 1). 13. Connect the liftgate release switch electrical connector (Figure 1). 14. Connect the liftgate release switch electrical connector (Figure 1). 15. Tighten the lower instruments panel cover screws securely. 16. Remove the two (2) screws that attach the lower console to the instrument panel support brackets (Figure 9). 17. Slide the cupholder out. 18. Remove the two (2) upper console attaching screws behind the cupholder (Figure 9). 19. Slide the console rearward and up to remove. 20. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM) (Figure 10). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7323 21. Install another mastic patch over the rear corner and left edge of the Body Control Module (BCM) (Figure 10). 22. Install the console assembly. 23. Install the upper console attaching screws behind the cupholder. Tighten the screws securely. Close the cupholder. 24. Install the two (2) lower console attaching screws (Figure 9). Tighten the screws securely. 25. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 26. 26. Turn the ignition switch to the ON position and exit the vehicle. 27. Connect the negative battery terminal. 28. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 29. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. D. Repair Passenger Airbag Wiring IMPORTANT: This section is only for vehicles with a "Passenger Squib Term Shorted to Ground" diagnostic trouble code. 1. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the two (2) screws that attach the lower console to the instrument panel support brackets (Figure 11). 3. Slide the cupholder out. 4. Remove the two (2) upper console attaching screws behind the cupholder (Figure 11). 5. Slide the console rearward and up to remove. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7324 6. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM) (Figure 12). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. 7. Install a mastic patch over the rear corner and left edge of the Body Control Module (BCM) (Figure 12). 8. Inspect the I/P wiring harness above the AECM and the BCM. Verify that the clip on the harness is installed into the hole on the back side of the left center console bracket (Figure 12). ^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the clip is missing or is damaged, install a new tie strap/clip (P/N 05016944AA) and insert the clip into the hole. 9. Install the console assembly. 10. Install the upper console attaching screws behind the cupholder. Tighten the screws securely (Figure 11). Close the cupholder. 11. Install the two (2) lower console attaching screws (Figure 11). Tighten the screws securely. 12. Disconnect the glove box door check straps and allow the door to open fully. 13. Working through the glove box opening, remove the four (4) screws that attach the passenger airbag module to the I/P bracket (Figure 13). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7325 14. Using a large flat-tipped screwdriver, pry the module up to unsnap the door from the trim pad and lift it away from the snaps (Figure 14). 15. Hold the passenger airbag module door and raise the module from the opening. DO NOT disconnect the airbag module electrical connectors. 16. Inspect the I/P wiring harness just behind the passenger airbag connectors (Figure 15). Any chafed or cut wires should be repaired per the Wiring Repair. 17. Install a mastic patch on the edge of the passenger airbag module near the electrical connectors (Figure 15). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7326 18. Inspect the passenger airbag module takeout on the I/P wiring harness near the vertical support bracket attached to the lip support tube (Figure 16). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. 19. Install a mastic patch on the bottom edge of the support bracket just below the existing plastic edge cover (Figure 16). 20. Install the passenger airbag module into the I/P. Tighten the module attaching screws to 50 in-lbs (6 Nm) 21. Connect the glove box door check straps and then close the glove box door. 22. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 23. 23. Install the lower steering column cover (Figure 1). 24. Connect the parking hand brake linkage (Figure 1). 25. Connect the liftgate release switch electrical connector (Figure 1). 26. Tighten the lower steering column cover screws securely. 27. Turn the ignition switch to the ON position and exit the vehicle. 28. Connect the negative battery terminal. 29. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 30. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Wiring Repair Procedure IMPORTANT: If airbag system wiring is found chafed or damaged, the wiring should be repaired using the procedure listed below. ^ If the plastic wire covering is chafed but the wiring strands are NOT damaged: Tape the damaged area with high quality electrical tape. ^ If the plastic wire covering is chafed and the wiring strands are damaged: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7327 1. Cut the damaged wire in two. 2. Strip 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing, P/N 04778570, on one end of the wire. 4. Spread the strands of the wire apart on both of the exposed wire ends. 5. Push the two wire ends together until the strands of the wire are close to the insulation. 6. Twist the wires together. 7. Solder the connection together using rosin core solder. 8. Center the heat shrink tubing over the repair area and apply heat with a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out both ends of the tubing. 9. Secure the wire to the harness to prevent chafing or damage to the insulation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > NHTSA99V113000 > May > 99 > Recall 99V113000: Inadvertent Air Bag Deployment Air Bag: All Technical Service Bulletins Recall 99V113000: Inadvertent Air Bag Deployment The wiring that initiates the driver and/or passenger air bag could electrically short circuit to ground. A short circuit to ground that exists immediately after turning the ignition key to the "ON" or "START" position can cause the air bag(s) to inadvertently deploy. Inadvertent air bag deployment can injure a front seat occupant. Dealers will perform an electronic diagnostic check. Any short circuits identified in either the driver's or passenger side air bag initiator wire circuit will be repaired. Owner notification began August 2, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 085993 > Nov > 93 > Instrument Panel - Squeak/Rattle From Right Side Air Bag: All Technical Service Bulletins Instrument Panel - Squeak/Rattle From Right Side NO.: 08-59-93 GROUP: Electrical DATE: Nov. 19, 1993 SUBJECT: Right Side Instrument Panel Squeak/Rattle Noise MODELS: 1994 (AS) Caravan/Voyager/Town & Country SYMPTOM/CONDITION: A squeak or rattle may be heard coming from the right side of the Instrument Panel (IP) when driving on rough road surfaces. DIAGNOSIS: Visually inspect the position of the Passenger Air Bag (PAB) in the opening of the IP. If the PAB is not centered and/or flush with the surface of the IP, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves repositioning the PAB in the IP opening. 1. Disconnect the negative battery cable. 2. Disengage the two glove box door check straps to allow for access to the four PAB attaching screws. 3. Loosen the four black PAB attaching screws facing the glove box door until the PAB can be easily moved in the IP opening. 4. Center the PAB in the IP opening. Use firm hand pressure to push down on the PAB door to ensure the PAB maintains the centered position and is held flush to under-flush with the IP surface while tightening the four PAB attaching screws to 50 In.Lbs. (5.7 N-m). 5. Reattach the two glove box door check straps. 6. Reconnect the negative battery cable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 23-11-50-90 0.2 Hrs. FAILURE CODE: 51 - Improperly Installed Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service Air Bag: All Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 7341 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 085993 > Nov > 93 > Instrument Panel - Squeak/Rattle From Right Side Air Bag: All Technical Service Bulletins Instrument Panel - Squeak/Rattle From Right Side NO.: 08-59-93 GROUP: Electrical DATE: Nov. 19, 1993 SUBJECT: Right Side Instrument Panel Squeak/Rattle Noise MODELS: 1994 (AS) Caravan/Voyager/Town & Country SYMPTOM/CONDITION: A squeak or rattle may be heard coming from the right side of the Instrument Panel (IP) when driving on rough road surfaces. DIAGNOSIS: Visually inspect the position of the Passenger Air Bag (PAB) in the opening of the IP. If the PAB is not centered and/or flush with the surface of the IP, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves repositioning the PAB in the IP opening. 1. Disconnect the negative battery cable. 2. Disengage the two glove box door check straps to allow for access to the four PAB attaching screws. 3. Loosen the four black PAB attaching screws facing the glove box door until the PAB can be easily moved in the IP opening. 4. Center the PAB in the IP opening. Use firm hand pressure to push down on the PAB door to ensure the PAB maintains the centered position and is held flush to under-flush with the IP surface while tightening the four PAB attaching screws to 50 In.Lbs. (5.7 N-m). 5. Reattach the two glove box door check straps. 6. Reconnect the negative battery cable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 23-11-50-90 0.2 Hrs. FAILURE CODE: 51 - Improperly Installed Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 7351 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment Technical Service Bulletin # 818 Date: 990701 Recall - Inadvertent Airbag Deployment July 1999 Dealer Service Instructions for: Safety Recall No. 818 Airbag System Wiring Models 1994 - 1995 (AS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth Voyager/Grand Voyager IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service as determined by using the DIAL VIP System. Subject The wiring that initiates the driver and/or passenger airbags on about 935,000 of the above vehicles may electrically short circuit to ground. A short circuit to ground that exists immediately after turning the ignition key to the "ON" or "START" position can cause the airbag(s) to inadvertently deply. Inadvertent airbag deployment can injure a front seat occupant. Repair A mastic patch must be installed on every vehicle. In addition, a diagnostic test of the airbag system must be performed. Shorted initiator (squib) wiring must be repaired (which may involve replacing the clockspring). If the rear wiper motor must be replace. Alternate Transportation If inspection determines that clockspring and/or rear wiper motor replacement is required and the vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7356 Use one of the table labor operation numbers and time allowances shown. Add the cost of the parts used plus applicable dealer allowance to your claim. Use the labor operation number and time allowance shown if an owner requires replacement of a rear wiper motor at some time in the future after the recall has already been completed. Parts Return If a REMANUFACTURED rear wiper motor was ordered: Removed rear wiper motors must be returned for core credit as quickly as possible using the Mopar Core Return Procedure on your DIAL terminal. You can access the procedure from Option 4 on the Parts System menu, then select Function 10. If a NEW rear wiper motor was ordered: Removed rear wiper motors must be returned to the Warranty Material Return Center. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing and material return instructions. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7357 DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD818". Owner Notification and Service Scheduling Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7358 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7359 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Provided with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Parts Information A. Mastic Patch Part Number Description 55275444AB Mastic Patch Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Mastic Patches to service about 25% of those vehicles. B. Clockspring Assembly Package Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7360 Part Number Description CCXR8181 Clockspring with Speed Control CCLR8182 Clockspring without Speed Control Each package contains a clockspring and a mastic patch. Due to the small number of involved vehicles expected to require clockspring replacement, each dealer will receive one clockspring for vehicles equipped with speed control. No clockspring assemblies for vehicles without speed control will be distributed initially. Additional clockspring packages should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require clockspring replacement. C. Tie Strap/Clips and Heat Shrink Tubing In addition, each dealer will receive one package often (10) tie strap/clips (P/N 05016944AA) and ten (10) pieces of heat shrink tubing (P/N 04778570) to repair damaged wiring if necessary. Additional tie strap/clips and heat shrink tubing may be ordered as necessary. D. Rear Wiper Motor Assembly Part Number Description R4673326 Remanufactured Rear Wiper Motor Assembly OR 04673326 New Rear Wiper Motor Assembly Due to the small number of involved vehicles expected to require rear wiper motor replacement, no wiper motors will be distributed initially. Wiper motors should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require rear wiper motor replacement. A. Install Mastic Patch & Check For Airbag System Diagnostic Trouble Codes (DTC's): 1. Turn on the rear wiper motor and allow it to run for several cycles, then turn it off. 2. Remove the five (5) steering column cover attaching screws and lower the cover (Figure 1). 3. Disconnect the liftgate release switch electrical connector (Figure 1). 4. Disconnect the parking hand brake linkage. 5. Set the lower steering column cover aside. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7361 6. Install the provided mastic patch on the right edge of the fuse/relay/kneeblocker bracket (Figure 2). 7. Insert the Super Card 2 into the DRB III(R) (Scan Tool) and then using cable CH7020, connect the DRB III to the underdash diagnostic connector (blue connector to the right of the steering column) and power it up. 8. Use the arrow keys and select # 1 - DRB III STAND ALONE on the DRB III MAIN MENU Screen. 9. Turn the ignition key tot he "ON" position. 10. Use the arrow keys and select # 1 - 1983-1997 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU Screen. 11. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the SUPERCARD MAIN MENU Screen. 12. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU Screen. 13. Use the arrow keys and select # 6 - PASSIVE RESTRAINTS on the SELECT SYSTEM Screen. 14. Use the arrow keys and select # 1 - AIRBAG on the SELECT RESTRAINT SYSTEM Screen. 15. Use the arrow keys and select # 2 - READ DTC'S on the SELECT FUNCTION Screen. 16. Use the arrow keys and select # 1 - ACTIVE on the DTC TYPE Screen. 17. Record all active DTC's for future reference. 18. Press the PAGE BACK key to return to the DTC TYPE Screen. 19. Use the arrow keys and select # 2- STORED on the DTC TYPE Screen. 20. Record all stored DTC's for future reference. 21. Press the PAGE BACK key to continue. 22. Use the arrow keys and select ERASE DTC'S on the DTC Screen (if DTC'S were present). 23. Press the PAGE BACK key to continue. 24. Turn the ignition key off and disconnect the DRB III. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7362 25. If the airbag system has one or more of the three DTC's in the table, proceed as shown in the table. If no airbag system DTC's exist, continue with Step 26. NOTE: Refer to the appropriate Diagnostic Manual for the proper diagnostic and repair procedures on any airbag system diagnostic trouble codes other than those listed above. 26. Install the lower steering column cover (Figure 1). 27. Connect the parking hand brake linkage. 28. Connect the liftgate release switch electrical connector (Figure 1). 29. Tighten the lower steering column cover screws securely. 30. Return the vehicle to the customer. No further action is necessary. B. Replace Rear Wiper Motor IMPORTANT: This section is only for vehicles with a "Loss of Ignition Run Only" diagnostic trouble code. 1. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the liftgate wiper arm assembly. 3. Open and raise the liftgate. 4. Remove the two (2) speaker grille/courtesy lamp assemblies (Figure 3). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7363 5. Remove the plugs at the ends of the assist handle and remove the handle attaching screws (Figure 3). 6. Remove the two (2) plugs at the lower corners of the trim panel and remove the lower trim panel screws (Figure 3). 7. Remove the two (2) trim panel screws located in the speaker grille openings (Figure 3). 8. Remove the two (2) plugs near the speaker grille openings in the center of the trim panel and remove the screws (Figure 3). 9. Remove the six (6) trim panel screws along the top edge and upper sides of the trim panel (Figure 3). 10. Disengage the frog leg clips around the perimeter of the trim panel and remove the trim panel from the liftgate. 11. Disconnect the wiper motor electrical connector (Figure 4). 12. Remove the five (5) wiper motor bracket mounting screws (Figure 4). Remove the wiper motor and bracket assembly from the liftgate and set it aside. 13. Install the remanufactured or new rear wiper motor and bracket assembly into the liftgate. Torque the five (5) attaching screws to 35 in-lbs (4 Nm). 14. Connect the wiper motor electrical connector. 15. Position the liftgate trim panel on the liftgate and engage the frog-leg clips around the perimeter of the panel. 16. Install the six (6) screws along the top and upper sides of the trim panel (Figure 3). CAUTION: DO NOT over tighten screws as this could damage the trim panel or strip the screws. 17. Install the two (2) screws located in the speaker grille openings (Figure 3). 18. Install the two (2) screws and plugs in the center of the trim panel (Figure 3). 19. Install the two (2) screws and plugs in the lower trim panel comers (Figure 3). 20. Install the assist handle with the two (2) screws (Figure 3). Install the handle screw plugs. 21. Connect the courtesy lamp electrical connectors and install the speaker grille/courtesy lamp assemblies. 22. Close the liftgate. 23. Install the liftgate wiper arm assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7364 24. In the fuse block located under the instrument panel, replace the rear wiper motor/airbag fuse (Fuse # 13) with a new 20 amp fuse (Figure 5). 25. ^ If any other airbag system diagnostic trouble codes were detected and must be still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 26. 26. Install the lower steering column cover (Figure 1). 27. Connect the parking hand brake linkage. 28. Connect the liftgate release switch electrical connector (Figure 1). 29. Tighten the lower steering column cover screws securely. 30. Turn the ignition switch to the ON position and exit the vehicle. 31. Connect the negative battery terminal. 32. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 33. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. C. Repair Driver Airbag Wiring and.or Replace Clockspring IMPORTANT: This section is only for vehicles with a "Driver Squib Term Shorted to Ground" diagnostic trouble code. 1. Place the steering wheel in the straight ahead position. 2. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 3. Remove the upper and lower steering column shrouds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7365 4. Inspect the clockspring wiring pigtail routed along the steering column for cuts or chafing (Figure 6). ^ If NO cuts or chafing of the clockspring pigtail is found, continue with Step 5. ^ If cuts or chafing of the clockspring pigtail is found, but no wire strands have been damaged, repair the clockspring wires by taping the damaged area with high quality electrical tape and tie strap as shown in Figure 6. ^ If cuts or chafing of the clockspring pigtail is found and internal wire strands have been damaged, replace the clockspring assembly as follows: a. Remove the four (4) airbag module retaining nuts from the back side of the steering wheel, disconnect the airbag module electrical connector and then remove the airbag module from the steering wheel and set it aside (inflator side down/face up for safety). b. Disconnect the speed control switch connector (if equipped). c. Disconnect the horn connector. d. Remove the steering wheel retaining nut and then using a steering wheel puller (Special Tool C-3428B), remove the steering wheel. e. Disconnect the clockspring wiring connector near the top of the fuse block and unclip the wiring pigtail from the steering column. f. Disconnect the clockspring wiring connector from the back of the clockspring. g. Unclip the clockspring assembly locating fingers from the steering column and then remove and discard the clockspring. h. Snap the new clockspring onto the steering column. i. Route the clockspring pigtail down the steering column such that the section of the I/P wiring harness that connects to the ignition switch is between the pigtail and the steering column. Secure the clockspring pigtail to the I/P wiring harness with a tie strap (P/N 05016944AA) (Figure 6). j. Connect the clockspring pigtail to the I/P wiring harness connector. Secure the clockspring pigtail to the I/P wiring harness near the fuse/relay/kneeblocker bracket with a tie strap (P/N 05016944AA) (Figure 6). k. Install the steering wheel. Torque the steering wheel retaining nut to 45 ft-lbs (61 Nm). l. Connect the horn connector. m. Connect the speed control switch connector (if equipped). n. Connect the airbag module electrical connector and install the airbag module onto the steering wheel. Torque the airbag module retaining nuts to 90 in-lbs (10 Nm). 5. Install the upper and lower steering column shrouds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7366 6. Inspect the I/P wiring harness where it is routed past the brake pedal support to verify that the harness tie strap/clip is secured into the hole (Figure 7). ^ If the tie strap/clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 05016944AA) and insert the clip into the hole. 7. Install another mastic patch on the edge of the brake pedal support bracket to prevent damage to the I/P wiring harness as it routes up past the fuse block (Figure 7). 8. Remove the relay access cover. 9. Inspect the I/P wiring harness and verify that the harness tie strap/clip has been inserted into the tab off of the fuse/relay/kneeblocker bracket (Figure 8). ^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 0516944AA) and insert the clip into the hole. 10. Install another mastic patch to the outboard end of the steel tube that routes the transmission shifter cable and the steering column support bracket closest to the I/P wiring harness (Figure 8). 11. Install the relay access cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7367 12. Install the lower steering column cover (Figure 1). 13. Connect the liftgate release switch electrical connector (Figure 1). 14. Connect the liftgate release switch electrical connector (Figure 1). 15. Tighten the lower instruments panel cover screws securely. 16. Remove the two (2) screws that attach the lower console to the instrument panel support brackets (Figure 9). 17. Slide the cupholder out. 18. Remove the two (2) upper console attaching screws behind the cupholder (Figure 9). 19. Slide the console rearward and up to remove. 20. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM) (Figure 10). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7368 21. Install another mastic patch over the rear corner and left edge of the Body Control Module (BCM) (Figure 10). 22. Install the console assembly. 23. Install the upper console attaching screws behind the cupholder. Tighten the screws securely. Close the cupholder. 24. Install the two (2) lower console attaching screws (Figure 9). Tighten the screws securely. 25. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 26. 26. Turn the ignition switch to the ON position and exit the vehicle. 27. Connect the negative battery terminal. 28. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 29. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. D. Repair Passenger Airbag Wiring IMPORTANT: This section is only for vehicles with a "Passenger Squib Term Shorted to Ground" diagnostic trouble code. 1. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the two (2) screws that attach the lower console to the instrument panel support brackets (Figure 11). 3. Slide the cupholder out. 4. Remove the two (2) upper console attaching screws behind the cupholder (Figure 11). 5. Slide the console rearward and up to remove. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7369 6. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM) (Figure 12). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. 7. Install a mastic patch over the rear corner and left edge of the Body Control Module (BCM) (Figure 12). 8. Inspect the I/P wiring harness above the AECM and the BCM. Verify that the clip on the harness is installed into the hole on the back side of the left center console bracket (Figure 12). ^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the clip is missing or is damaged, install a new tie strap/clip (P/N 05016944AA) and insert the clip into the hole. 9. Install the console assembly. 10. Install the upper console attaching screws behind the cupholder. Tighten the screws securely (Figure 11). Close the cupholder. 11. Install the two (2) lower console attaching screws (Figure 11). Tighten the screws securely. 12. Disconnect the glove box door check straps and allow the door to open fully. 13. Working through the glove box opening, remove the four (4) screws that attach the passenger airbag module to the I/P bracket (Figure 13). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7370 14. Using a large flat-tipped screwdriver, pry the module up to unsnap the door from the trim pad and lift it away from the snaps (Figure 14). 15. Hold the passenger airbag module door and raise the module from the opening. DO NOT disconnect the airbag module electrical connectors. 16. Inspect the I/P wiring harness just behind the passenger airbag connectors (Figure 15). Any chafed or cut wires should be repaired per the Wiring Repair. 17. Install a mastic patch on the edge of the passenger airbag module near the electrical connectors (Figure 15). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7371 18. Inspect the passenger airbag module takeout on the I/P wiring harness near the vertical support bracket attached to the lip support tube (Figure 16). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. 19. Install a mastic patch on the bottom edge of the support bracket just below the existing plastic edge cover (Figure 16). 20. Install the passenger airbag module into the I/P. Tighten the module attaching screws to 50 in-lbs (6 Nm) 21. Connect the glove box door check straps and then close the glove box door. 22. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 23. 23. Install the lower steering column cover (Figure 1). 24. Connect the parking hand brake linkage (Figure 1). 25. Connect the liftgate release switch electrical connector (Figure 1). 26. Tighten the lower steering column cover screws securely. 27. Turn the ignition switch to the ON position and exit the vehicle. 28. Connect the negative battery terminal. 29. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 30. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Wiring Repair Procedure IMPORTANT: If airbag system wiring is found chafed or damaged, the wiring should be repaired using the procedure listed below. ^ If the plastic wire covering is chafed but the wiring strands are NOT damaged: Tape the damaged area with high quality electrical tape. ^ If the plastic wire covering is chafed and the wiring strands are damaged: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7372 1. Cut the damaged wire in two. 2. Strip 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing, P/N 04778570, on one end of the wire. 4. Spread the strands of the wire apart on both of the exposed wire ends. 5. Push the two wire ends together until the strands of the wire are close to the insulation. 6. Twist the wires together. 7. Solder the connection together using rosin core solder. 8. Center the heat shrink tubing over the repair area and apply heat with a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out both ends of the tubing. 9. Secure the wire to the harness to prevent chafing or damage to the insulation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > NHTSA99V113000 > May > 99 > Recall 99V113000: Inadvertent Air Bag Deployment Air Bag: All Technical Service Bulletins Recall 99V113000: Inadvertent Air Bag Deployment The wiring that initiates the driver and/or passenger air bag could electrically short circuit to ground. A short circuit to ground that exists immediately after turning the ignition key to the "ON" or "START" position can cause the air bag(s) to inadvertently deploy. Inadvertent air bag deployment can injure a front seat occupant. Dealers will perform an electronic diagnostic check. Any short circuits identified in either the driver's or passenger side air bag initiator wire circuit will be repaired. Owner notification began August 2, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations Dash And Console Mounted Component Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations > Page 7379 Air Bag Module And Connector Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service Precautions > Customer Safety Information Air Bag: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service Precautions > Customer Safety Information > Page 7382 Air Bag: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service Precautions > Page 7383 Air Bag: Description and Operation DRIVER SIDE The driver side airbag module, located in the center of the steering wheel, contains the airbag cushion and its supporting components. The airbag cushion and inflator are attached to and sealed by the airbag module housing. The driver side inflator is mounted on the back of the module housing. When supplied with the proper electrical signal the inflator produces a gas and discharges it directly into the cushion. A decorative, protective cover is fitted on the front of the driver airbag module housing. PASSENGER SIDE This bag assembly utilizes a canister of a compressed, inert gas to inflate the bag, instead of the sodium azide charge used previously. The pressure of the canister is monitored by a non-serviceable pressure switch, which is built into the canister. The pressure switch is wired to and monitored by the air bag control module. When supplied with the proper electrical signal the inflator produces a gas and discharges it directly into the cushion. A decorative, protective cover is fitted over the airbag module. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Testing and Inspection > Component Tests and General Diagnostics Air Bag: Component Tests and General Diagnostics GENERAL INSPECTION A visual inspection consists of physically looking for possible cause of a malfunction. A careful and thorough visual inspection of components may quickly identify malfunction cause and eliminate need for diagnostic testing. If a malfunction is not resolved by visual inspection, proceed with diagnostic testing. 1. On models equipped with front impact sensors, ensure both sensors are properly install with three fasteners each. 2. On all models, turn ignition switch to On. 3. If air bag warning lamp does not light, proceed with diagnostic testing. 4. If air bag warning lamp fails to go out after ten seconds, proceed with diagnostic testing. 5. Check air bag control module (ACM) case and brackets for dents, cracks or deformities. 6. Check ACM connectors and lock levers for damage and terminals for deformities. 7. Remove air bag module as outlined under Component Service. 8. Never attempt to measure circuit resistance of air bag module even with a specified tester. 9. Check air bag pad cover for dents, cracks or deformities. 10. Check air bag module for dents, cracks or deformities. 11. Check hooks and connectors for damage, terminals for deformities and harness for binds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 7386 Air Bag: Scan Tool Testing and Procedures Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures Air Bag: Service and Repair Air Bag Module Disposal Procedures See: AIR BAG MODULE DISPOSAL After deployment, air bag module should be placed in a plastic bag and disposed of in same manner as any other scrap parts, except that following points should be carefully noted during disposal. 1. When handling deployed air bag assembly, face shield and rubber gloves should be worn. 2. There may be material adhered to air bag module that could irritate eyes and/or skin. If any irritation develops, seek medical attention. Note following: a. If sinus or throat irritation is encountered during air bag removal, exit vehicle and breath fresh air. b. If material does come in contact with eyes and/or skin, immediately rinse affected area with a large amount of cool, clean water. c. If sinus, throat, skin or any other type of irritation continues, consult a physician. 3. After handling a deployed air bag assembly, wash hands and rinse thoroughly with water. 4. Inflator will be quite hot immediately after deployment, wait 30 minutes to allow air bag to cool. 5. Do not put water or oil on air bag after deployment. 6. Put deployed air bag in a hermetically sealed container and discard it. 7. Use a vacuum cleaner to remove any residual powder from vehicle interior as follows: a. Work from outside to center of vehicle. b. Vacuum A/C, vent, defroster and heater ducts. c. Run blower motor on low speed and vacuum any powder expelled from plenum. d. It may be necessary to vacuum interior of vehicle a second time to ensure all powder is recovered. 8. An air bag that has been deployed should be removed as outlined under Driver Air Bag Assembly, Replace See: Driver Side Airbag Module Replacement or Passenger Air Bag Assembly, Replace. See: Passenger Side Airbag Module Replacement 9. Prior to removing a deployed air bag assembly, place tape over air bag exhaust vents. 10. Before disposing of a vehicle equipped with air bag(s), or prior to disposing of air bag module, module must be deployed as follows: a. If vehicle is to be scrapped, deploy air bag(s) inside vehicle. b. If vehicle is to continue in service, air bags must be removed and deployed outside vehicle. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 7389 Air Bag: Service and Repair Driver Side Airbag Module Replacement Fig. 1 Driver Air Bag Module Replacement DRIVER AIR BAG MODULE, REPLACE 1. Disarm air bag as outlined under Air Bag System Disarming and Arming. See: Air Bag(s) Arming and Disarming/Service and Repair 2. Remove air bag module nuts for steering wheel. 3. Lift module and disconnect electrical connector. 4. Remove module. 5. Reverse procedure to install and tighten nuts to specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 7390 Air Bag: Service and Repair Passenger Side Airbag Module Replacement PASSENGER AIR BAG MODULE, REPLACE, CARAVAN, TOWN & COUNTRY & VOYAGER 1. Disarm air bag as outlined under Air Bag System Disarming and Arming. See: Air Bag(s) Arming and Disarming/Service and Repair 2. If air bag module has deployed, roll or fold air bag toward instrument panel, then close door over air bag and tape closed. 3. Disconnect glove compartment door and allow door to fully open. 4. Remove air bag module mounting screws. 5. Pry module up with large flat tipped screws driver to unsnap door from trim pad, then lift away from snaps. 6. Hold on to door, lift module from opening and rest module on trim pad. 7. Disconnect electrical connectors and remove module. 8. Reverse procedure to install and tighten screws to specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Locations Air Bag Control Module And Body Control Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Diagrams > Air Bag Control Module 4 Way Connector Air Bag Control Module Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Diagrams > Air Bag Control Module 4 Way Connector > Page 7396 Air Bag Control Module Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Diagrams > Air Bag Control Module 4 Way Connector > Page 7397 Airbag System Control Module Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information Supplemental Restraint System (SRS) Control Module: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information > Page 7400 Supplemental Restraint System (SRS) Control Module: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information > Page 7401 Supplemental Restraint System (SRS) Control Module: Vehicle Damage Warnings CAUTION: Before disconnecting any control module connector, make sure the ignition is "OFF" and the battery is disconnected. Failure to do so could damage the module. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Page 7402 Supplemental Restraint System (SRS) Control Module: Description and Operation OPERATION The deceleration or g-force resulting from the impact of a front-end collision causes the electronic sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying the air bags. The total time between determining to deploy and deflation of the air bag is 1/10th of a second. SELF DIAGNOSTIC FUNCTIONS Whenever the ignition key is turned to the "RUN" or "START" position, the air bag control module (ACM) performs a lamp check by turning the AIR BAG warning lamp ON. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. The air bag system is monitored by the ACM. The ACM monitors critical input and output circuits within the air bag system, making sure they are operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The ACM provides diagnostic information about the air bag system to the technician through the DRB via the CCD bus. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Testing and Inspection > Component Tests and General Diagnostics Supplemental Restraint System (SRS) Control Module: Component Tests and General Diagnostics GENERAL INSPECTION A visual inspection consists of physically looking for possible cause of a malfunction. A careful and thorough visual inspection of components may quickly identify malfunction cause and eliminate need for diagnostic testing. If a malfunction is not resolved by visual inspection, proceed with diagnostic testing. 1. On models equipped with front impact sensors, ensure both sensors are properly install with three fasteners each. 2. On all models, turn ignition switch to On. 3. If air bag warning lamp does not light, proceed with diagnostic testing. 4. If air bag warning lamp fails to go out after ten seconds, proceed with diagnostic testing. 5. Check air bag control module (ACM) case and brackets for dents, cracks or deformities. 6. Check ACM connectors and lock levers for damage and terminals for deformities. 7. Remove air bag module as outlined under Component Service. 8. Never attempt to measure circuit resistance of air bag module even with a specified tester. 9. Check air bag pad cover for dents, cracks or deformities. 10. Check air bag module for dents, cracks or deformities. 11. Check hooks and connectors for damage, terminals for deformities and harness for binds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 7405 Supplemental Restraint System (SRS) Control Module: Scan Tool Testing and Procedures Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Testing and Inspection > Page 7406 Supplemental Restraint System (SRS) Control Module: Service and Repair AIR BAG CONTROL (ACM), REPLACE 1. Disarm air bag system as outlined under Air Bag System Disarming and Arming. See: Air Bag(s) Arming and Disarming/Service and Repair 2. Remove screws attaching lower console to instrument panel support bracket. 3. Remove upper console attaching screws behind cup holder, then slide console to rear and up to remove. 4. Disconnect ACM wiring and remove module, then remove ACM mounting screws. 5. Reverse procedure to install and tighten screws to specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7411 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7412 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7413 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7414 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7415 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7416 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment Technical Service Bulletin # 818 Date: 990701 Recall - Inadvertent Airbag Deployment July 1999 Dealer Service Instructions for: Safety Recall No. 818 Airbag System Wiring Models 1994 - 1995 (AS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth Voyager/Grand Voyager IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service as determined by using the DIAL VIP System. Subject The wiring that initiates the driver and/or passenger airbags on about 935,000 of the above vehicles may electrically short circuit to ground. A short circuit to ground that exists immediately after turning the ignition key to the "ON" or "START" position can cause the airbag(s) to inadvertently deply. Inadvertent airbag deployment can injure a front seat occupant. Repair A mastic patch must be installed on every vehicle. In addition, a diagnostic test of the airbag system must be performed. Shorted initiator (squib) wiring must be repaired (which may involve replacing the clockspring). If the rear wiper motor must be replace. Alternate Transportation If inspection determines that clockspring and/or rear wiper motor replacement is required and the vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7425 Use one of the table labor operation numbers and time allowances shown. Add the cost of the parts used plus applicable dealer allowance to your claim. Use the labor operation number and time allowance shown if an owner requires replacement of a rear wiper motor at some time in the future after the recall has already been completed. Parts Return If a REMANUFACTURED rear wiper motor was ordered: Removed rear wiper motors must be returned for core credit as quickly as possible using the Mopar Core Return Procedure on your DIAL terminal. You can access the procedure from Option 4 on the Parts System menu, then select Function 10. If a NEW rear wiper motor was ordered: Removed rear wiper motors must be returned to the Warranty Material Return Center. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing and material return instructions. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7426 DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD818". Owner Notification and Service Scheduling Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7427 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7428 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Provided with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Parts Information A. Mastic Patch Part Number Description 55275444AB Mastic Patch Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Mastic Patches to service about 25% of those vehicles. B. Clockspring Assembly Package Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7429 Part Number Description CCXR8181 Clockspring with Speed Control CCLR8182 Clockspring without Speed Control Each package contains a clockspring and a mastic patch. Due to the small number of involved vehicles expected to require clockspring replacement, each dealer will receive one clockspring for vehicles equipped with speed control. No clockspring assemblies for vehicles without speed control will be distributed initially. Additional clockspring packages should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require clockspring replacement. C. Tie Strap/Clips and Heat Shrink Tubing In addition, each dealer will receive one package often (10) tie strap/clips (P/N 05016944AA) and ten (10) pieces of heat shrink tubing (P/N 04778570) to repair damaged wiring if necessary. Additional tie strap/clips and heat shrink tubing may be ordered as necessary. D. Rear Wiper Motor Assembly Part Number Description R4673326 Remanufactured Rear Wiper Motor Assembly OR 04673326 New Rear Wiper Motor Assembly Due to the small number of involved vehicles expected to require rear wiper motor replacement, no wiper motors will be distributed initially. Wiper motors should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require rear wiper motor replacement. A. Install Mastic Patch & Check For Airbag System Diagnostic Trouble Codes (DTC's): 1. Turn on the rear wiper motor and allow it to run for several cycles, then turn it off. 2. Remove the five (5) steering column cover attaching screws and lower the cover (Figure 1). 3. Disconnect the liftgate release switch electrical connector (Figure 1). 4. Disconnect the parking hand brake linkage. 5. Set the lower steering column cover aside. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7430 6. Install the provided mastic patch on the right edge of the fuse/relay/kneeblocker bracket (Figure 2). 7. Insert the Super Card 2 into the DRB III(R) (Scan Tool) and then using cable CH7020, connect the DRB III to the underdash diagnostic connector (blue connector to the right of the steering column) and power it up. 8. Use the arrow keys and select # 1 - DRB III STAND ALONE on the DRB III MAIN MENU Screen. 9. Turn the ignition key tot he "ON" position. 10. Use the arrow keys and select # 1 - 1983-1997 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU Screen. 11. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the SUPERCARD MAIN MENU Screen. 12. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU Screen. 13. Use the arrow keys and select # 6 - PASSIVE RESTRAINTS on the SELECT SYSTEM Screen. 14. Use the arrow keys and select # 1 - AIRBAG on the SELECT RESTRAINT SYSTEM Screen. 15. Use the arrow keys and select # 2 - READ DTC'S on the SELECT FUNCTION Screen. 16. Use the arrow keys and select # 1 - ACTIVE on the DTC TYPE Screen. 17. Record all active DTC's for future reference. 18. Press the PAGE BACK key to return to the DTC TYPE Screen. 19. Use the arrow keys and select # 2- STORED on the DTC TYPE Screen. 20. Record all stored DTC's for future reference. 21. Press the PAGE BACK key to continue. 22. Use the arrow keys and select ERASE DTC'S on the DTC Screen (if DTC'S were present). 23. Press the PAGE BACK key to continue. 24. Turn the ignition key off and disconnect the DRB III. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7431 25. If the airbag system has one or more of the three DTC's in the table, proceed as shown in the table. If no airbag system DTC's exist, continue with Step 26. NOTE: Refer to the appropriate Diagnostic Manual for the proper diagnostic and repair procedures on any airbag system diagnostic trouble codes other than those listed above. 26. Install the lower steering column cover (Figure 1). 27. Connect the parking hand brake linkage. 28. Connect the liftgate release switch electrical connector (Figure 1). 29. Tighten the lower steering column cover screws securely. 30. Return the vehicle to the customer. No further action is necessary. B. Replace Rear Wiper Motor IMPORTANT: This section is only for vehicles with a "Loss of Ignition Run Only" diagnostic trouble code. 1. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the liftgate wiper arm assembly. 3. Open and raise the liftgate. 4. Remove the two (2) speaker grille/courtesy lamp assemblies (Figure 3). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7432 5. Remove the plugs at the ends of the assist handle and remove the handle attaching screws (Figure 3). 6. Remove the two (2) plugs at the lower corners of the trim panel and remove the lower trim panel screws (Figure 3). 7. Remove the two (2) trim panel screws located in the speaker grille openings (Figure 3). 8. Remove the two (2) plugs near the speaker grille openings in the center of the trim panel and remove the screws (Figure 3). 9. Remove the six (6) trim panel screws along the top edge and upper sides of the trim panel (Figure 3). 10. Disengage the frog leg clips around the perimeter of the trim panel and remove the trim panel from the liftgate. 11. Disconnect the wiper motor electrical connector (Figure 4). 12. Remove the five (5) wiper motor bracket mounting screws (Figure 4). Remove the wiper motor and bracket assembly from the liftgate and set it aside. 13. Install the remanufactured or new rear wiper motor and bracket assembly into the liftgate. Torque the five (5) attaching screws to 35 in-lbs (4 Nm). 14. Connect the wiper motor electrical connector. 15. Position the liftgate trim panel on the liftgate and engage the frog-leg clips around the perimeter of the panel. 16. Install the six (6) screws along the top and upper sides of the trim panel (Figure 3). CAUTION: DO NOT over tighten screws as this could damage the trim panel or strip the screws. 17. Install the two (2) screws located in the speaker grille openings (Figure 3). 18. Install the two (2) screws and plugs in the center of the trim panel (Figure 3). 19. Install the two (2) screws and plugs in the lower trim panel comers (Figure 3). 20. Install the assist handle with the two (2) screws (Figure 3). Install the handle screw plugs. 21. Connect the courtesy lamp electrical connectors and install the speaker grille/courtesy lamp assemblies. 22. Close the liftgate. 23. Install the liftgate wiper arm assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7433 24. In the fuse block located under the instrument panel, replace the rear wiper motor/airbag fuse (Fuse # 13) with a new 20 amp fuse (Figure 5). 25. ^ If any other airbag system diagnostic trouble codes were detected and must be still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 26. 26. Install the lower steering column cover (Figure 1). 27. Connect the parking hand brake linkage. 28. Connect the liftgate release switch electrical connector (Figure 1). 29. Tighten the lower steering column cover screws securely. 30. Turn the ignition switch to the ON position and exit the vehicle. 31. Connect the negative battery terminal. 32. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 33. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. C. Repair Driver Airbag Wiring and.or Replace Clockspring IMPORTANT: This section is only for vehicles with a "Driver Squib Term Shorted to Ground" diagnostic trouble code. 1. Place the steering wheel in the straight ahead position. 2. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 3. Remove the upper and lower steering column shrouds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7434 4. Inspect the clockspring wiring pigtail routed along the steering column for cuts or chafing (Figure 6). ^ If NO cuts or chafing of the clockspring pigtail is found, continue with Step 5. ^ If cuts or chafing of the clockspring pigtail is found, but no wire strands have been damaged, repair the clockspring wires by taping the damaged area with high quality electrical tape and tie strap as shown in Figure 6. ^ If cuts or chafing of the clockspring pigtail is found and internal wire strands have been damaged, replace the clockspring assembly as follows: a. Remove the four (4) airbag module retaining nuts from the back side of the steering wheel, disconnect the airbag module electrical connector and then remove the airbag module from the steering wheel and set it aside (inflator side down/face up for safety). b. Disconnect the speed control switch connector (if equipped). c. Disconnect the horn connector. d. Remove the steering wheel retaining nut and then using a steering wheel puller (Special Tool C-3428B), remove the steering wheel. e. Disconnect the clockspring wiring connector near the top of the fuse block and unclip the wiring pigtail from the steering column. f. Disconnect the clockspring wiring connector from the back of the clockspring. g. Unclip the clockspring assembly locating fingers from the steering column and then remove and discard the clockspring. h. Snap the new clockspring onto the steering column. i. Route the clockspring pigtail down the steering column such that the section of the I/P wiring harness that connects to the ignition switch is between the pigtail and the steering column. Secure the clockspring pigtail to the I/P wiring harness with a tie strap (P/N 05016944AA) (Figure 6). j. Connect the clockspring pigtail to the I/P wiring harness connector. Secure the clockspring pigtail to the I/P wiring harness near the fuse/relay/kneeblocker bracket with a tie strap (P/N 05016944AA) (Figure 6). k. Install the steering wheel. Torque the steering wheel retaining nut to 45 ft-lbs (61 Nm). l. Connect the horn connector. m. Connect the speed control switch connector (if equipped). n. Connect the airbag module electrical connector and install the airbag module onto the steering wheel. Torque the airbag module retaining nuts to 90 in-lbs (10 Nm). 5. Install the upper and lower steering column shrouds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7435 6. Inspect the I/P wiring harness where it is routed past the brake pedal support to verify that the harness tie strap/clip is secured into the hole (Figure 7). ^ If the tie strap/clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 05016944AA) and insert the clip into the hole. 7. Install another mastic patch on the edge of the brake pedal support bracket to prevent damage to the I/P wiring harness as it routes up past the fuse block (Figure 7). 8. Remove the relay access cover. 9. Inspect the I/P wiring harness and verify that the harness tie strap/clip has been inserted into the tab off of the fuse/relay/kneeblocker bracket (Figure 8). ^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 0516944AA) and insert the clip into the hole. 10. Install another mastic patch to the outboard end of the steel tube that routes the transmission shifter cable and the steering column support bracket closest to the I/P wiring harness (Figure 8). 11. Install the relay access cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7436 12. Install the lower steering column cover (Figure 1). 13. Connect the liftgate release switch electrical connector (Figure 1). 14. Connect the liftgate release switch electrical connector (Figure 1). 15. Tighten the lower instruments panel cover screws securely. 16. Remove the two (2) screws that attach the lower console to the instrument panel support brackets (Figure 9). 17. Slide the cupholder out. 18. Remove the two (2) upper console attaching screws behind the cupholder (Figure 9). 19. Slide the console rearward and up to remove. 20. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM) (Figure 10). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7437 21. Install another mastic patch over the rear corner and left edge of the Body Control Module (BCM) (Figure 10). 22. Install the console assembly. 23. Install the upper console attaching screws behind the cupholder. Tighten the screws securely. Close the cupholder. 24. Install the two (2) lower console attaching screws (Figure 9). Tighten the screws securely. 25. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 26. 26. Turn the ignition switch to the ON position and exit the vehicle. 27. Connect the negative battery terminal. 28. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 29. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. D. Repair Passenger Airbag Wiring IMPORTANT: This section is only for vehicles with a "Passenger Squib Term Shorted to Ground" diagnostic trouble code. 1. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the two (2) screws that attach the lower console to the instrument panel support brackets (Figure 11). 3. Slide the cupholder out. 4. Remove the two (2) upper console attaching screws behind the cupholder (Figure 11). 5. Slide the console rearward and up to remove. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7438 6. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM) (Figure 12). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. 7. Install a mastic patch over the rear corner and left edge of the Body Control Module (BCM) (Figure 12). 8. Inspect the I/P wiring harness above the AECM and the BCM. Verify that the clip on the harness is installed into the hole on the back side of the left center console bracket (Figure 12). ^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the clip is missing or is damaged, install a new tie strap/clip (P/N 05016944AA) and insert the clip into the hole. 9. Install the console assembly. 10. Install the upper console attaching screws behind the cupholder. Tighten the screws securely (Figure 11). Close the cupholder. 11. Install the two (2) lower console attaching screws (Figure 11). Tighten the screws securely. 12. Disconnect the glove box door check straps and allow the door to open fully. 13. Working through the glove box opening, remove the four (4) screws that attach the passenger airbag module to the I/P bracket (Figure 13). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7439 14. Using a large flat-tipped screwdriver, pry the module up to unsnap the door from the trim pad and lift it away from the snaps (Figure 14). 15. Hold the passenger airbag module door and raise the module from the opening. DO NOT disconnect the airbag module electrical connectors. 16. Inspect the I/P wiring harness just behind the passenger airbag connectors (Figure 15). Any chafed or cut wires should be repaired per the Wiring Repair. 17. Install a mastic patch on the edge of the passenger airbag module near the electrical connectors (Figure 15). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7440 18. Inspect the passenger airbag module takeout on the I/P wiring harness near the vertical support bracket attached to the lip support tube (Figure 16). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. 19. Install a mastic patch on the bottom edge of the support bracket just below the existing plastic edge cover (Figure 16). 20. Install the passenger airbag module into the I/P. Tighten the module attaching screws to 50 in-lbs (6 Nm) 21. Connect the glove box door check straps and then close the glove box door. 22. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 23. 23. Install the lower steering column cover (Figure 1). 24. Connect the parking hand brake linkage (Figure 1). 25. Connect the liftgate release switch electrical connector (Figure 1). 26. Tighten the lower steering column cover screws securely. 27. Turn the ignition switch to the ON position and exit the vehicle. 28. Connect the negative battery terminal. 29. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 30. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Wiring Repair Procedure IMPORTANT: If airbag system wiring is found chafed or damaged, the wiring should be repaired using the procedure listed below. ^ If the plastic wire covering is chafed but the wiring strands are NOT damaged: Tape the damaged area with high quality electrical tape. ^ If the plastic wire covering is chafed and the wiring strands are damaged: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7441 1. Cut the damaged wire in two. 2. Strip 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing, P/N 04778570, on one end of the wire. 4. Spread the strands of the wire apart on both of the exposed wire ends. 5. Push the two wire ends together until the strands of the wire are close to the insulation. 6. Twist the wires together. 7. Solder the connection together using rosin core solder. 8. Center the heat shrink tubing over the repair area and apply heat with a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out both ends of the tubing. 9. Secure the wire to the harness to prevent chafing or damage to the insulation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 7447 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment Technical Service Bulletin # 818 Date: 990701 Recall - Inadvertent Airbag Deployment July 1999 Dealer Service Instructions for: Safety Recall No. 818 Airbag System Wiring Models 1994 - 1995 (AS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth Voyager/Grand Voyager IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service as determined by using the DIAL VIP System. Subject The wiring that initiates the driver and/or passenger airbags on about 935,000 of the above vehicles may electrically short circuit to ground. A short circuit to ground that exists immediately after turning the ignition key to the "ON" or "START" position can cause the airbag(s) to inadvertently deply. Inadvertent airbag deployment can injure a front seat occupant. Repair A mastic patch must be installed on every vehicle. In addition, a diagnostic test of the airbag system must be performed. Shorted initiator (squib) wiring must be repaired (which may involve replacing the clockspring). If the rear wiper motor must be replace. Alternate Transportation If inspection determines that clockspring and/or rear wiper motor replacement is required and the vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7452 Use one of the table labor operation numbers and time allowances shown. Add the cost of the parts used plus applicable dealer allowance to your claim. Use the labor operation number and time allowance shown if an owner requires replacement of a rear wiper motor at some time in the future after the recall has already been completed. Parts Return If a REMANUFACTURED rear wiper motor was ordered: Removed rear wiper motors must be returned for core credit as quickly as possible using the Mopar Core Return Procedure on your DIAL terminal. You can access the procedure from Option 4 on the Parts System menu, then select Function 10. If a NEW rear wiper motor was ordered: Removed rear wiper motors must be returned to the Warranty Material Return Center. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing and material return instructions. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7453 DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD818". Owner Notification and Service Scheduling Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7454 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7455 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Provided with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Parts Information A. Mastic Patch Part Number Description 55275444AB Mastic Patch Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Mastic Patches to service about 25% of those vehicles. B. Clockspring Assembly Package Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7456 Part Number Description CCXR8181 Clockspring with Speed Control CCLR8182 Clockspring without Speed Control Each package contains a clockspring and a mastic patch. Due to the small number of involved vehicles expected to require clockspring replacement, each dealer will receive one clockspring for vehicles equipped with speed control. No clockspring assemblies for vehicles without speed control will be distributed initially. Additional clockspring packages should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require clockspring replacement. C. Tie Strap/Clips and Heat Shrink Tubing In addition, each dealer will receive one package often (10) tie strap/clips (P/N 05016944AA) and ten (10) pieces of heat shrink tubing (P/N 04778570) to repair damaged wiring if necessary. Additional tie strap/clips and heat shrink tubing may be ordered as necessary. D. Rear Wiper Motor Assembly Part Number Description R4673326 Remanufactured Rear Wiper Motor Assembly OR 04673326 New Rear Wiper Motor Assembly Due to the small number of involved vehicles expected to require rear wiper motor replacement, no wiper motors will be distributed initially. Wiper motors should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require rear wiper motor replacement. A. Install Mastic Patch & Check For Airbag System Diagnostic Trouble Codes (DTC's): 1. Turn on the rear wiper motor and allow it to run for several cycles, then turn it off. 2. Remove the five (5) steering column cover attaching screws and lower the cover (Figure 1). 3. Disconnect the liftgate release switch electrical connector (Figure 1). 4. Disconnect the parking hand brake linkage. 5. Set the lower steering column cover aside. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7457 6. Install the provided mastic patch on the right edge of the fuse/relay/kneeblocker bracket (Figure 2). 7. Insert the Super Card 2 into the DRB III(R) (Scan Tool) and then using cable CH7020, connect the DRB III to the underdash diagnostic connector (blue connector to the right of the steering column) and power it up. 8. Use the arrow keys and select # 1 - DRB III STAND ALONE on the DRB III MAIN MENU Screen. 9. Turn the ignition key tot he "ON" position. 10. Use the arrow keys and select # 1 - 1983-1997 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU Screen. 11. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the SUPERCARD MAIN MENU Screen. 12. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU Screen. 13. Use the arrow keys and select # 6 - PASSIVE RESTRAINTS on the SELECT SYSTEM Screen. 14. Use the arrow keys and select # 1 - AIRBAG on the SELECT RESTRAINT SYSTEM Screen. 15. Use the arrow keys and select # 2 - READ DTC'S on the SELECT FUNCTION Screen. 16. Use the arrow keys and select # 1 - ACTIVE on the DTC TYPE Screen. 17. Record all active DTC's for future reference. 18. Press the PAGE BACK key to return to the DTC TYPE Screen. 19. Use the arrow keys and select # 2- STORED on the DTC TYPE Screen. 20. Record all stored DTC's for future reference. 21. Press the PAGE BACK key to continue. 22. Use the arrow keys and select ERASE DTC'S on the DTC Screen (if DTC'S were present). 23. Press the PAGE BACK key to continue. 24. Turn the ignition key off and disconnect the DRB III. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7458 25. If the airbag system has one or more of the three DTC's in the table, proceed as shown in the table. If no airbag system DTC's exist, continue with Step 26. NOTE: Refer to the appropriate Diagnostic Manual for the proper diagnostic and repair procedures on any airbag system diagnostic trouble codes other than those listed above. 26. Install the lower steering column cover (Figure 1). 27. Connect the parking hand brake linkage. 28. Connect the liftgate release switch electrical connector (Figure 1). 29. Tighten the lower steering column cover screws securely. 30. Return the vehicle to the customer. No further action is necessary. B. Replace Rear Wiper Motor IMPORTANT: This section is only for vehicles with a "Loss of Ignition Run Only" diagnostic trouble code. 1. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the liftgate wiper arm assembly. 3. Open and raise the liftgate. 4. Remove the two (2) speaker grille/courtesy lamp assemblies (Figure 3). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7459 5. Remove the plugs at the ends of the assist handle and remove the handle attaching screws (Figure 3). 6. Remove the two (2) plugs at the lower corners of the trim panel and remove the lower trim panel screws (Figure 3). 7. Remove the two (2) trim panel screws located in the speaker grille openings (Figure 3). 8. Remove the two (2) plugs near the speaker grille openings in the center of the trim panel and remove the screws (Figure 3). 9. Remove the six (6) trim panel screws along the top edge and upper sides of the trim panel (Figure 3). 10. Disengage the frog leg clips around the perimeter of the trim panel and remove the trim panel from the liftgate. 11. Disconnect the wiper motor electrical connector (Figure 4). 12. Remove the five (5) wiper motor bracket mounting screws (Figure 4). Remove the wiper motor and bracket assembly from the liftgate and set it aside. 13. Install the remanufactured or new rear wiper motor and bracket assembly into the liftgate. Torque the five (5) attaching screws to 35 in-lbs (4 Nm). 14. Connect the wiper motor electrical connector. 15. Position the liftgate trim panel on the liftgate and engage the frog-leg clips around the perimeter of the panel. 16. Install the six (6) screws along the top and upper sides of the trim panel (Figure 3). CAUTION: DO NOT over tighten screws as this could damage the trim panel or strip the screws. 17. Install the two (2) screws located in the speaker grille openings (Figure 3). 18. Install the two (2) screws and plugs in the center of the trim panel (Figure 3). 19. Install the two (2) screws and plugs in the lower trim panel comers (Figure 3). 20. Install the assist handle with the two (2) screws (Figure 3). Install the handle screw plugs. 21. Connect the courtesy lamp electrical connectors and install the speaker grille/courtesy lamp assemblies. 22. Close the liftgate. 23. Install the liftgate wiper arm assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7460 24. In the fuse block located under the instrument panel, replace the rear wiper motor/airbag fuse (Fuse # 13) with a new 20 amp fuse (Figure 5). 25. ^ If any other airbag system diagnostic trouble codes were detected and must be still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 26. 26. Install the lower steering column cover (Figure 1). 27. Connect the parking hand brake linkage. 28. Connect the liftgate release switch electrical connector (Figure 1). 29. Tighten the lower steering column cover screws securely. 30. Turn the ignition switch to the ON position and exit the vehicle. 31. Connect the negative battery terminal. 32. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 33. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. C. Repair Driver Airbag Wiring and.or Replace Clockspring IMPORTANT: This section is only for vehicles with a "Driver Squib Term Shorted to Ground" diagnostic trouble code. 1. Place the steering wheel in the straight ahead position. 2. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 3. Remove the upper and lower steering column shrouds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7461 4. Inspect the clockspring wiring pigtail routed along the steering column for cuts or chafing (Figure 6). ^ If NO cuts or chafing of the clockspring pigtail is found, continue with Step 5. ^ If cuts or chafing of the clockspring pigtail is found, but no wire strands have been damaged, repair the clockspring wires by taping the damaged area with high quality electrical tape and tie strap as shown in Figure 6. ^ If cuts or chafing of the clockspring pigtail is found and internal wire strands have been damaged, replace the clockspring assembly as follows: a. Remove the four (4) airbag module retaining nuts from the back side of the steering wheel, disconnect the airbag module electrical connector and then remove the airbag module from the steering wheel and set it aside (inflator side down/face up for safety). b. Disconnect the speed control switch connector (if equipped). c. Disconnect the horn connector. d. Remove the steering wheel retaining nut and then using a steering wheel puller (Special Tool C-3428B), remove the steering wheel. e. Disconnect the clockspring wiring connector near the top of the fuse block and unclip the wiring pigtail from the steering column. f. Disconnect the clockspring wiring connector from the back of the clockspring. g. Unclip the clockspring assembly locating fingers from the steering column and then remove and discard the clockspring. h. Snap the new clockspring onto the steering column. i. Route the clockspring pigtail down the steering column such that the section of the I/P wiring harness that connects to the ignition switch is between the pigtail and the steering column. Secure the clockspring pigtail to the I/P wiring harness with a tie strap (P/N 05016944AA) (Figure 6). j. Connect the clockspring pigtail to the I/P wiring harness connector. Secure the clockspring pigtail to the I/P wiring harness near the fuse/relay/kneeblocker bracket with a tie strap (P/N 05016944AA) (Figure 6). k. Install the steering wheel. Torque the steering wheel retaining nut to 45 ft-lbs (61 Nm). l. Connect the horn connector. m. Connect the speed control switch connector (if equipped). n. Connect the airbag module electrical connector and install the airbag module onto the steering wheel. Torque the airbag module retaining nuts to 90 in-lbs (10 Nm). 5. Install the upper and lower steering column shrouds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7462 6. Inspect the I/P wiring harness where it is routed past the brake pedal support to verify that the harness tie strap/clip is secured into the hole (Figure 7). ^ If the tie strap/clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 05016944AA) and insert the clip into the hole. 7. Install another mastic patch on the edge of the brake pedal support bracket to prevent damage to the I/P wiring harness as it routes up past the fuse block (Figure 7). 8. Remove the relay access cover. 9. Inspect the I/P wiring harness and verify that the harness tie strap/clip has been inserted into the tab off of the fuse/relay/kneeblocker bracket (Figure 8). ^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 0516944AA) and insert the clip into the hole. 10. Install another mastic patch to the outboard end of the steel tube that routes the transmission shifter cable and the steering column support bracket closest to the I/P wiring harness (Figure 8). 11. Install the relay access cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7463 12. Install the lower steering column cover (Figure 1). 13. Connect the liftgate release switch electrical connector (Figure 1). 14. Connect the liftgate release switch electrical connector (Figure 1). 15. Tighten the lower instruments panel cover screws securely. 16. Remove the two (2) screws that attach the lower console to the instrument panel support brackets (Figure 9). 17. Slide the cupholder out. 18. Remove the two (2) upper console attaching screws behind the cupholder (Figure 9). 19. Slide the console rearward and up to remove. 20. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM) (Figure 10). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7464 21. Install another mastic patch over the rear corner and left edge of the Body Control Module (BCM) (Figure 10). 22. Install the console assembly. 23. Install the upper console attaching screws behind the cupholder. Tighten the screws securely. Close the cupholder. 24. Install the two (2) lower console attaching screws (Figure 9). Tighten the screws securely. 25. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 26. 26. Turn the ignition switch to the ON position and exit the vehicle. 27. Connect the negative battery terminal. 28. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 29. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. D. Repair Passenger Airbag Wiring IMPORTANT: This section is only for vehicles with a "Passenger Squib Term Shorted to Ground" diagnostic trouble code. 1. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the two (2) screws that attach the lower console to the instrument panel support brackets (Figure 11). 3. Slide the cupholder out. 4. Remove the two (2) upper console attaching screws behind the cupholder (Figure 11). 5. Slide the console rearward and up to remove. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7465 6. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM) (Figure 12). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. 7. Install a mastic patch over the rear corner and left edge of the Body Control Module (BCM) (Figure 12). 8. Inspect the I/P wiring harness above the AECM and the BCM. Verify that the clip on the harness is installed into the hole on the back side of the left center console bracket (Figure 12). ^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the clip is missing or is damaged, install a new tie strap/clip (P/N 05016944AA) and insert the clip into the hole. 9. Install the console assembly. 10. Install the upper console attaching screws behind the cupholder. Tighten the screws securely (Figure 11). Close the cupholder. 11. Install the two (2) lower console attaching screws (Figure 11). Tighten the screws securely. 12. Disconnect the glove box door check straps and allow the door to open fully. 13. Working through the glove box opening, remove the four (4) screws that attach the passenger airbag module to the I/P bracket (Figure 13). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7466 14. Using a large flat-tipped screwdriver, pry the module up to unsnap the door from the trim pad and lift it away from the snaps (Figure 14). 15. Hold the passenger airbag module door and raise the module from the opening. DO NOT disconnect the airbag module electrical connectors. 16. Inspect the I/P wiring harness just behind the passenger airbag connectors (Figure 15). Any chafed or cut wires should be repaired per the Wiring Repair. 17. Install a mastic patch on the edge of the passenger airbag module near the electrical connectors (Figure 15). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7467 18. Inspect the passenger airbag module takeout on the I/P wiring harness near the vertical support bracket attached to the lip support tube (Figure 16). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. 19. Install a mastic patch on the bottom edge of the support bracket just below the existing plastic edge cover (Figure 16). 20. Install the passenger airbag module into the I/P. Tighten the module attaching screws to 50 in-lbs (6 Nm) 21. Connect the glove box door check straps and then close the glove box door. 22. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 23. 23. Install the lower steering column cover (Figure 1). 24. Connect the parking hand brake linkage (Figure 1). 25. Connect the liftgate release switch electrical connector (Figure 1). 26. Tighten the lower steering column cover screws securely. 27. Turn the ignition switch to the ON position and exit the vehicle. 28. Connect the negative battery terminal. 29. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 30. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Wiring Repair Procedure IMPORTANT: If airbag system wiring is found chafed or damaged, the wiring should be repaired using the procedure listed below. ^ If the plastic wire covering is chafed but the wiring strands are NOT damaged: Tape the damaged area with high quality electrical tape. ^ If the plastic wire covering is chafed and the wiring strands are damaged: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 7468 1. Cut the damaged wire in two. 2. Strip 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing, P/N 04778570, on one end of the wire. 4. Spread the strands of the wire apart on both of the exposed wire ends. 5. Push the two wire ends together until the strands of the wire are close to the insulation. 6. Twist the wires together. 7. Solder the connection together using rosin core solder. 8. Center the heat shrink tubing over the repair area and apply heat with a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out both ends of the tubing. 9. Secure the wire to the harness to prevent chafing or damage to the insulation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 7474 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Customer Safety Information Clockspring Assembly / Spiral Cable: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Customer Safety Information > Page 7477 Clockspring Assembly / Spiral Cable: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 7478 Clockspring Assembly / Spiral Cable: Description and Operation PURPOSE The clockspring, mounted on the steering wheel column, behind the steering wheel, is used to maintain a continuous electrical circuit between the wiring harness and the driver airbag module. CONSTRUCTION The clockspring assembly consists of a flat, ribbon like, electrically conductive tape, which winds and unwinds as the steering wheel is rotated. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 7479 Clockspring Assembly / Spiral Cable: Testing and Inspection Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Removal Clockspring Assembly / Spiral Cable: Service and Repair Removal REMOVAL 1. Disarm air bag as outlined. See: Air Bag(s) Arming and Disarming/Service and Repair 2. Set front wheels in straight ahead position. 3. Remove air bag module as outlined under Driver Air Bag Module, Replace. See: Air Bag/Service and Repair/Driver Side Airbag Module Replacement 4. Remove speed control switch and electrical connector, if equipped, or cover. 5. Disconnect horn electrical connector. 6. Remove steering wheel attaching nut; then remove steering wheel using suitable puller. 7. Remove upper and lower steering column shrouds. 8. Disconnect clockspring two and four way electrical connectors. 9. Lift clockspring locating fingers, then gently pull clockspring assembly from steering column. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Removal > Page 7482 Clockspring Assembly / Spiral Cable: Service and Repair Installation INSTALLATION 1. Snap clockspring on steering column. If clockspring is not properly positioned refer Centering procedure. See: Centering 2. Connect clockspring to instrument panel electrical connector, ensuring locator clips and lock tabs are properly positioned. 3. Install steering column shrouds. Ensure air bag wire is inside shrouds. 4. Ensure front wheels are in straight ahead position, then install steering wheel, ensuring hub flats align with clockspring. 5. Pull horn lead through small upper hole, then pull air bag and speed control leads through larger hole. Ensure leads are not pinched under steering wheel. 6. Connect horn and air bag electrical connectors at air bag module. 7. Install air bag module as outlined under Driver Air Bag Module, Replace. See: Air Bag/Service and Repair/Driver Side Airbag Module Replacement 8. Install speed control switch and electrical connector or uncover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Removal > Page 7483 Clockspring Assembly / Spiral Cable: Service and Repair Centering Fig. 43 Auto-locking clockspring CENTERING NOTE: If rotating part of clockspring is not properly positioned with steering column and front wheels, clockspring may fail during use. The following procedure must be used if clockspring is not known to be properly positioned. 1. Position front wheels straight ahead. 2. Depress plastic locking pins to disengage locking mechanism. 3. With locking mechanism disengaged, rotate clockspring rotor in clockwise direction to end of travel. Do not apply excessive force. 4. From end of travel, rotate clockspring rotor 2 1/2 turns in counterclockwise direction. The horn wire should be at top and squib wire at bottom. Visually inspect clockspring for bends or kinks; if indicated, replace clockspring. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Diagnostic Connector, Air Bag > Component Information > Locations CCD Data Link Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Diagnostic Connector, Air Bag > Component Information > Locations > Page 7487 Vehicle will be equipped with one of these three connectors Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations Located inside the Airbag Control Module (ACM) which is mounted on a bracket, just forward of. the center console. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information Impact Sensor: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 7493 Impact Sensor: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service Precautions > Page 7494 Impact Sensor: Description and Operation OPERATION The impact sensor provides verification of the direction and severity of the impact. One impact sensor is used. It is located inside the Airbag Control Module (ACM) which is mounted on a bracket, just forward of. the center console. The impact sensor is an accelerometer that senses deceleration. The deceleration pulses are sent to a microprocessor which contains a decision algorithm. When an impact is severe enough to require airbag protection, the ACM micro processor sends a signal that completes the electrical circuit to the driver and passenger airbags. The sensor is calibrated for the specific vehicle and reacts to the severity and direction of the impact. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Testing and Inspection > Component Tests and General Diagnostics Impact Sensor: Component Tests and General Diagnostics GENERAL INSPECTION A visual inspection consists of physically looking for possible cause of a malfunction. A careful and thorough visual inspection of components may quickly identify malfunction cause and eliminate need for diagnostic testing. If a malfunction is not resolved by visual inspection, proceed with diagnostic testing. 1. On all models, turn ignition switch to On. 2. If air bag warning lamp does not light, proceed with diagnostic testing. 3. If air bag warning lamp fails to go out after ten seconds, proceed with diagnostic testing. 4. Check air bag control module (ACM) case and brackets for dents, cracks or deformities. 5. Check ACM connectors and lock levers for damage and terminals for deformities. 6. Remove air bag module as outlined under Component Service. 7. Never attempt to measure circuit resistance of air bag module even with a specified tester. 8. Check air bag pad cover for dents, cracks or deformities. 9. Check air bag module for dents, cracks or deformities. 10. Check hooks and connectors for damage, terminals for deformities and harness for binds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 7497 Impact Sensor: Scan Tool Testing and Procedures Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Warning Lamp <--> [Malfunction Lamp / Indicator, Air Bag] > Component Information > Technical Service Bulletins > Airbag - Warning Light Illumination Air Bag Warning Lamp: Technical Service Bulletins Airbag - Warning Light Illumination NO: 08-07-98 GROUP: Electrical DATE: Mar. 6, 1998 SUBJECT: Airbag Warning Light illumination Caused By A Short in The Rear Wiper Motor/Circuit MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) DISCUSSION: Some subject vehicles may experience a short in the rear wiper motor/circuit causing fuse # 13 to blow which illuminates the Airbag Warning light in the instrument panel. When a short in the rear wiper motor/circuit causes fuse # 13 to blow, the Airbag Warning light is "ON" but the airbag system still receives power through fuse # 20 and is fully functional, providing the same occupant protection as when the light is not illuminated. However, when this condition occurs, it hides a proper warning if an airbag system fault were to occur. Due to the age of the involved vehicles, some owners may prefer to minimize their expense to turn off the Airbag Warning light. For owners seeking a less expensive alternative, if the rear wiper motor itself is the source of the short, the wiper motor wiring connector can be disconnected and isolated. Then, when fuse # 13 is replaced, the Airbag Warning light will be extinguished, allowing the Airbag Warning light to indicate real airbag system faults if they should occur. Use a DRB III to check for any stored airbag Diagnostic Trouble Codes (DTC's). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Warning Lamp <--> [Malfunction Lamp / Indicator, Air Bag] > Component Information > Technical Service Bulletins > Page 7502 Air Bag Warning Lamp: Locations Located in the Information Center. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Warning Lamp <--> [Malfunction Lamp / Indicator, Air Bag] > Component Information > Technical Service Bulletins > Page 7503 Air Bag Warning Lamp: Description and Operation PURPOSE The AIR BAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. See Testing and Inspection to find the cause of any customer complaint regarding the AIR BAG warning lamp, such as: Warning lamp does not come on at all - Warning lamp stays on See: Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Warning Lamp <--> [Malfunction Lamp / Indicator, Air Bag] > Component Information > Technical Service Bulletins > Page 7504 Air Bag Warning Lamp: Testing and Inspection Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Locations Air Bag Control Module And Body Control Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Diagrams > Air Bag Control Module 4 Way Connector Air Bag Control Module Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Diagrams > Air Bag Control Module 4 Way Connector > Page 7511 Air Bag Control Module Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Diagrams > Air Bag Control Module 4 Way Connector > Page 7512 Airbag System Control Module Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information Supplemental Restraint System (SRS) Control Module: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information > Page 7515 Supplemental Restraint System (SRS) Control Module: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Customer Safety Information > Page 7516 Supplemental Restraint System (SRS) Control Module: Vehicle Damage Warnings CAUTION: Before disconnecting any control module connector, make sure the ignition is "OFF" and the battery is disconnected. Failure to do so could damage the module. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Service Precautions > Page 7517 Supplemental Restraint System (SRS) Control Module: Description and Operation OPERATION The deceleration or g-force resulting from the impact of a front-end collision causes the electronic sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying the air bags. The total time between determining to deploy and deflation of the air bag is 1/10th of a second. SELF DIAGNOSTIC FUNCTIONS Whenever the ignition key is turned to the "RUN" or "START" position, the air bag control module (ACM) performs a lamp check by turning the AIR BAG warning lamp ON. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. The air bag system is monitored by the ACM. The ACM monitors critical input and output circuits within the air bag system, making sure they are operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The ACM provides diagnostic information about the air bag system to the technician through the DRB via the CCD bus. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Testing and Inspection > Component Tests and General Diagnostics Supplemental Restraint System (SRS) Control Module: Component Tests and General Diagnostics GENERAL INSPECTION A visual inspection consists of physically looking for possible cause of a malfunction. A careful and thorough visual inspection of components may quickly identify malfunction cause and eliminate need for diagnostic testing. If a malfunction is not resolved by visual inspection, proceed with diagnostic testing. 1. On models equipped with front impact sensors, ensure both sensors are properly install with three fasteners each. 2. On all models, turn ignition switch to On. 3. If air bag warning lamp does not light, proceed with diagnostic testing. 4. If air bag warning lamp fails to go out after ten seconds, proceed with diagnostic testing. 5. Check air bag control module (ACM) case and brackets for dents, cracks or deformities. 6. Check ACM connectors and lock levers for damage and terminals for deformities. 7. Remove air bag module as outlined under Component Service. 8. Never attempt to measure circuit resistance of air bag module even with a specified tester. 9. Check air bag pad cover for dents, cracks or deformities. 10. Check air bag module for dents, cracks or deformities. 11. Check hooks and connectors for damage, terminals for deformities and harness for binds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 7520 Supplemental Restraint System (SRS) Control Module: Scan Tool Testing and Procedures Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Supplemental Restraint System (SRS) Control Module <--> [Air Bag Control Module] > Component Information > Testing and Inspection > Page 7521 Supplemental Restraint System (SRS) Control Module: Service and Repair AIR BAG CONTROL (ACM), REPLACE 1. Disarm air bag system as outlined under Air Bag System Disarming and Arming. See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair 2. Remove screws attaching lower console to instrument panel support bracket. 3. Remove upper console attaching screws behind cup holder, then slide console to rear and up to remove. 4. Disconnect ACM wiring and remove module, then remove ACM mounting screws. 5. Reverse procedure to install and tighten screws to specifications. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least ten minutes after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 7527 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming ARMING 1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate SRS system is functioning correctly. 5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air Bag Systems/Testing and Inspection. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Tether Installation NUMBER: 23-029-08 GROUP: Body DATE: October 24, 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. B, DATED NOVEMBER 24, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DEALERS PLEASE NOTE, THIS IS REIMBURSABLE REGARDLESS OF VEHICLE AGE OR MILEAGE. SUBJECT: Child Seat Tether Anchor Installation OVERVIEW: This bulletin describes procedures to install Child Seat Tether Anchors based on Customer Request. NOTE: Dealers are encouraged to honor any customers request for the installation of the Child Seat Tether Anchors and Dealer reimbursement will be made by Chrysler regardless of vehicle age or mileage. See the Warranty Policy and Procedure Manual and or Warranty Bulletin D-08-33 for reimbursement detail. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shawdow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7533 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year and later. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. Chrysler is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. NOTE: This bulletin is provided to identify the parts and labor operation numbers necessary to install a Child Seat Tether Anchor. Each dealer is encouraged to install these kits based on customer request and Chrysler will reimburse any Chrysler / Dodge / or Jeep dealer installing these kits regardless of vehicle age or mileage. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7534 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7535 PARTS REQUIRED: POLICY: Customer Satisfaction, Reimbursable regardless of mileage or age. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7536 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7537 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7538 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7539 Child Seat Tether Attachment: Technical Service Bulletins Child Seat Tether Anchor - Labor/Parts Identification NUMBER: 23-35-99 Rev. A GROUP: Body DATE: Oct. 1, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-35-99 DATED SEPTEMBER 3, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES IN SOME TIME ALLOWANCES. SUBJECT: Child Seat Tether Anchors NOTE: THIS BULLETIN DOES NOT APPLY TO DAIMLERCHRYSLER CANADA DEALERS. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) LeBaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2000 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light truck in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7540 detailed instruction sheet. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7541 PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7542 POLICY: Customer Satisfaction Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7543 TIME ALLOWANCE: Failure Code: CG - Customer Satisfaction Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt: > 230394 > Jan > 94 > Middle Bench Seat Outer Seatbelt - High Extension Effort Seat Belt: Customer Interest Middle Bench Seat Outer Seatbelt - High Extension Effort NO: 23-03-94 GROUP: Body DATE: Jan. 21, 1994 SUBJECT: Middle Bench Seat Left Seat Belt MODELS: 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO SHORT WHEEL BASE (SWB) VEHICLES. SYMPTOM/CONDITION: High effort is required to extend the middle bench seat left seat belt or the seat belt will not return to the stowed position. DIAGNOSIS: Extend the seat belt. If high effort is required or the seat belt will not return, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves trimming the silencer pad on the back side of the left upper quarter trim panel. 1. Using the procedure outlined (steps 1-4) on Page 23-39 of the 1994 Town & Country/Caravan/Voyager Service Manual (Publication No. 81-370-4105) remove the left quarter trim insert. 2. Remove the silencer material from the back side of the upper quarter trim panel from the area shown in the illustration. 3. Reverse the procedure in step 1 to reinstall the interior trim. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 23-20-56-91 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 230394 > Jan > 94 > Middle Bench Seat Outer Seatbelt High Extension Effort Seat Belt: All Technical Service Bulletins Middle Bench Seat Outer Seatbelt - High Extension Effort NO: 23-03-94 GROUP: Body DATE: Jan. 21, 1994 SUBJECT: Middle Bench Seat Left Seat Belt MODELS: 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO SHORT WHEEL BASE (SWB) VEHICLES. SYMPTOM/CONDITION: High effort is required to extend the middle bench seat left seat belt or the seat belt will not return to the stowed position. DIAGNOSIS: Extend the seat belt. If high effort is required or the seat belt will not return, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves trimming the silencer pad on the back side of the left upper quarter trim panel. 1. Using the procedure outlined (steps 1-4) on Page 23-39 of the 1994 Town & Country/Caravan/Voyager Service Manual (Publication No. 81-370-4105) remove the left quarter trim insert. 2. Remove the silencer material from the back side of the upper quarter trim panel from the area shown in the illustration. 3. Reverse the procedure in step 1 to reinstall the interior trim. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 23-20-56-91 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 7557 Seat Belt: Service and Repair Front Outboard Seat Belt Left Side Front Outboard Seat Belt Right Side FRONT SEAT BELTS OUTBOARD SHOULDER HARNESS/LAP BELT REMOVAL 1. Remove shoulder harness turning loop. 2. Remove B-pillar or quarter trim panels as necessary to gain access to belt retractor. 3. Remove bolt holding retractor and lower lap belt anchor to B-pillar. 4. Separate belt from vehicle. OUTBOARD SHOULDER HARNESS/LAP BELT INSTALLATION Reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 7558 Front Inboard Seat Belt Buckle INBOARD BUCKLE REMOVAL 1. Remove bolt holding seat belt buckle to seat riser. 2. separate buckle from seat riser. 3. Disconnect seat belt sensor wire connector, if equipped. INBOARD BUCKLE INSTALLATION Reverse the preceding operation. Rear Shoulder/Lap Belts Left Side Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 7559 Rear Shoulder/Lap Belts Right Side REAR SEAT BELT OUTBOARD SHOULDER HARNESS/LAP BELT REMOVAL 1. Remove interior trim as necessary to gain access to belt retractor. 2. Remove bolt holding lower lap belt anchor to floor bracket. 3. Remove bolt holding belt retractor to inner quarter panel. 4. Separate belt from vehicle. OUTBOARD SHOULDER HARNESS LAP BELT INSTALLATION Reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair Seat Belt Height Adjuster: Service and Repair Shoulder Harness Height Adjuster 1. Remove B-pillar trim or quarter trim panel. 2. Remove bolts holding adjuster to B-pillar. 3. Separate adjuster from vehicle. 4. Reverse the preceding operation for installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7568 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7569 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7570 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7571 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7572 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7573 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations Located inside the Airbag Control Module (ACM) which is mounted on a bracket, just forward of. the center console. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information Impact Sensor: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 7579 Impact Sensor: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Page 7580 Impact Sensor: Description and Operation OPERATION The impact sensor provides verification of the direction and severity of the impact. One impact sensor is used. It is located inside the Airbag Control Module (ACM) which is mounted on a bracket, just forward of. the center console. The impact sensor is an accelerometer that senses deceleration. The deceleration pulses are sent to a microprocessor which contains a decision algorithm. When an impact is severe enough to require airbag protection, the ACM micro processor sends a signal that completes the electrical circuit to the driver and passenger airbags. The sensor is calibrated for the specific vehicle and reacts to the severity and direction of the impact. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Testing and Inspection > Component Tests and General Diagnostics Impact Sensor: Component Tests and General Diagnostics GENERAL INSPECTION A visual inspection consists of physically looking for possible cause of a malfunction. A careful and thorough visual inspection of components may quickly identify malfunction cause and eliminate need for diagnostic testing. If a malfunction is not resolved by visual inspection, proceed with diagnostic testing. 1. On all models, turn ignition switch to On. 2. If air bag warning lamp does not light, proceed with diagnostic testing. 3. If air bag warning lamp fails to go out after ten seconds, proceed with diagnostic testing. 4. Check air bag control module (ACM) case and brackets for dents, cracks or deformities. 5. Check ACM connectors and lock levers for damage and terminals for deformities. 6. Remove air bag module as outlined under Component Service. 7. Never attempt to measure circuit resistance of air bag module even with a specified tester. 8. Check air bag pad cover for dents, cracks or deformities. 9. Check air bag module for dents, cracks or deformities. 10. Check hooks and connectors for damage, terminals for deformities and harness for binds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 7583 Impact Sensor: Scan Tool Testing and Procedures Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations Body Control Module System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7590 Keyless Entry Module: Diagrams Remote Keyless Entry Module Connectors Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Programming Module Keyless Entry Module: Service and Repair Programming Module PROGRAMMING RKE MODULE The RKE module is capable of retaining up to 4 different VAC(s) when vehicle battery power is interrupted. Replacement or additional key fob transmitter VAC(s) (maximum 4) can be programmed into the Body Control Module (BCM). A functional key fob transmitter is required to program the BCM to accept the new VAC. If a functional key fob transmitter is not available, a scan tool (DRB) can be used to program the BCM. (1) Using a functional key fob, unlock the vehicle and disarm the Vehicle Theft Alarm (2) Insert ignition key into the ignition switch. (3) Switch ignition to RUN position without starting engine. (4) On a functional key fob, actuate and hold the UNLOCK button for a minimum four seconds (maximum ten seconds). (5) While holding UNLOCK button, and before ten seconds passes, actuate and release the PANIC button. A single chime will sound to verify that the RKE module is set to receive the new VAC. (6) Within 30 seconds of the chime, actuate any key on each new key fob transmitter. After 30 seconds or when ignition switch is turned OF{ the RKE module will end the programming mode. A single chime will sound to verify that the RKE module will no longer receive additional VAC(s). (7) When VAC programming is complete, turn OFF ignition switch and verify RKE system operation using each key fob. NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror systems. If a primary key fob is being replaced, the memory seat and mirror module will require programming. Refer to Group 8R, Power Seats for proper (data link) programming procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Programming Module > Page 7593 Keyless Entry Module: Service and Repair Remote Keyless Entry Module Replacement REMOVAL (1) Remove instrument panel top cover. (2) Remove screws holding RKE module to instrument panel. (3) Disconnect wire connector from RKE module. (4) Remove module. INSTALLATION Reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Remote Keyless Entry - Transmitter Malfunction Keyless Entry Transmitter: Technical Service Bulletins Remote Keyless Entry - Transmitter Malfunction NO.: 08-51-93 GROUP: Electrical DATE: Oct. 15, 1993 SUBJECT: Remote Keyless Entry System MODELS: 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country SYMPTOM/CONDITION: Some vehicles may require the Remote Keyless Entry (RKE) transmitter button(s) to be repeatedly depressed to obtain a response from the system. NOTE: AS-BODY VEHICLES RESPOND DIFFERENTLY TO RKE INPUTS WHEN COMPARED TO THE SIMILAR SYSTEM USED PREVIOUSLY ON AC/AY-BODY VEHICLES. AS-BODY VEHICLES HAVE A SHORT DELAY AFTER A RKE TRANSMITTER BUTTON IS DEPRESSED BEFORE EITHER THE ILLUMINATED ENTRY OR HORN CHIRP IS ACTIVATED. THIS DELAY IS NORMAL FOR AS-BODY VEHICLES BUT DID NOT OCCUR ON PREVIOUS AC/AY-BODY VEHICLES. DIAGNOSIS: Open the transmitter case to access the batteries. If a white pentastar is NOT readily visible on the printed circuit board, perform the repair procedure. If the printed circuit board has a white pentastar, this TSB does not apply and the procedure outlined beginning on page 214 of the Body Diagnostic Procedures Manual (Publication No. 81- 699-0442) should be used. PARTS REQUIRED: 2 Transmitter 4469341 REPAIR PROCEDURE: This bulletin involves replacing the RKE transmitters. 1. Obtain two new transmitters (P/N 4469341) and verify they have a white pentastar on their printed circuit boards. 2. Using the procedure outlined on page 8P-5 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105) program the RKE transmitters. NOTE: IN THE SPIRIT OF CUSTOMER ONE, AND IN CASE THEY WERE NOT TOLD AT THE TIME OF DELIVERY, THIS WOULD BE AN EXCELLENT TIME TO ADVISE THE CUSTOMER THE HORN CHIRP FEATURE CAN BE CANCELED WHEN THE NEW RKE TRANSMITTERS ARE PROGRAMMED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-28-90 0.2 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Page 7598 Keyless Entry Transmitter: Description and Operation Normal operation range is up to about a distance of 7 meters (23 ft.) of the vehicle. Range may be better or worse depending on the environment around the vehicle. Closeness to a radio frequency transmitter such as a radio station tower may degrade operational range, while range in an open field will be enhanced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Transmitter Programming Keyless Entry Transmitter: Service and Repair Transmitter Programming PROGRAM REMOTE KEYLESS ENTRY - Open and lower glove box door. - Locate program line a dark green wire with a molded insulator on the end. Located behind and lower end of the glove box. - Turn ignition switch to the ON position. - Connect the program line from the Remote Keyless Entry Module to ground. the door locks will lock and unlock to indicate the receiver is ready to receive transmitter code. Liftgate solenoid will not cycle. - Press any button on the transmitter to set code. If there is a second transmitter it has to be set at this time. The locks will cycle to confirm programming. - Disconnect the program line from ground. This returns the system to its normal operation mode. - Install glove box to original position. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Transmitter Programming > Page 7601 Keyless Entry Transmitter: Service and Repair Battery Replacement The batteries can be removed without special tools and are readily available at local retail stores. The recommended battery is Duracell DL 2016 or equivalent. Battery life is about one to two years. CAUTION: Do not touch the battery terminals or handle the batteries any more than necessary. Hands must be clean dry. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions Driver/Vehicle Information Display: Technical Service Bulletins Instruments Calibration/Diagnostics Revisions NUMBER: 08-78-94 GROUP: Electrical DATE: Dec. 30, 1994 REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** Models: 1994 Town & Country/Caravan/Voyager - Publication No. 81-370-4105 DESCRIPTION OF CHANGES Calibration Description & Self Diagnosis Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions > Page 7606 8C-2 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions > Page 7607 8C-4 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7610 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7611 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7612 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7613 Driver/Vehicle Information Display: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7614 Warning Lamp Center Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7615 Driver/Vehicle Information Display: Electrical Diagrams Electronic Vehicle Info. Center (EVIC) W/ Transmission Control (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7616 Electronic Vehicle Info. Center (EVIC) W/ Transmission Control (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7617 Warning Lamp Center (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7618 Warning Lamp Center (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Page 7619 Driver/Vehicle Information Display: Service and Repair 1. Remove instrument panel cluster bezel and left panel silencer, then disconnect parking brake linkage. 2. Remove five cover attaching screws and lower cover, then disconnect all wire connectors. 3. Remove steering column covers, then remove four cluster screws. 4. On models with electronic instruments, proceed as follows: a. Remove four cluster securing screws and four mask housing screws b. Rotate mask down, then disconnect buttons and PRNDL indicator. Fig. 9 Mechanical Instrument Cluster Removal 5. On models with mechanical instruments, rotate cluster and disconnect connector. 6. On all models, remove two transmission indicator screws and cluster. 7. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Audio Control Relay > Component Information > Locations Micro Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Door Speaker Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Door Speaker > Page 7632 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Door Speaker > Page 7633 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Audio Control Relay > Component Information > Locations Micro Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Body Control Module System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 7641 Keyless Entry Module: Diagrams Remote Keyless Entry Module Connectors Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Programming Module Keyless Entry Module: Service and Repair Programming Module PROGRAMMING RKE MODULE The RKE module is capable of retaining up to 4 different VAC(s) when vehicle battery power is interrupted. Replacement or additional key fob transmitter VAC(s) (maximum 4) can be programmed into the Body Control Module (BCM). A functional key fob transmitter is required to program the BCM to accept the new VAC. If a functional key fob transmitter is not available, a scan tool (DRB) can be used to program the BCM. (1) Using a functional key fob, unlock the vehicle and disarm the Vehicle Theft Alarm (2) Insert ignition key into the ignition switch. (3) Switch ignition to RUN position without starting engine. (4) On a functional key fob, actuate and hold the UNLOCK button for a minimum four seconds (maximum ten seconds). (5) While holding UNLOCK button, and before ten seconds passes, actuate and release the PANIC button. A single chime will sound to verify that the RKE module is set to receive the new VAC. (6) Within 30 seconds of the chime, actuate any key on each new key fob transmitter. After 30 seconds or when ignition switch is turned OF{ the RKE module will end the programming mode. A single chime will sound to verify that the RKE module will no longer receive additional VAC(s). (7) When VAC programming is complete, turn OFF ignition switch and verify RKE system operation using each key fob. NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror systems. If a primary key fob is being replaced, the memory seat and mirror module will require programming. Refer to Group 8R, Power Seats for proper (data link) programming procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Programming Module > Page 7644 Keyless Entry Module: Service and Repair Remote Keyless Entry Module Replacement REMOVAL (1) Remove instrument panel top cover. (2) Remove screws holding RKE module to instrument panel. (3) Disconnect wire connector from RKE module. (4) Remove module. INSTALLATION Reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7650 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7651 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7652 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7653 Trailer Connector: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7654 Trailer Tow System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7659 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7660 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7661 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7662 Trailer Connector: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7663 Trailer Tow System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Locations Compass Mini-trip Module Connectors Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions Trip Computer: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 7669 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 7670 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 7671 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 7672 Trip Computer: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 7673 Trip Computer: Connector Views Overhead Console Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 7674 Trip Computer: Electrical Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 7675 Overhead Console Lamp With Mini-Trip Computer (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 7676 Overhead Console Lamp With Mini-Trip Computer (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Page 7677 Trip Computer: Description and Operation Compass Mini-trip Module PURPOSE: The compass/mini-trip module is located in the overhead console. It displays to the driver the direction the vehicle is traveling and the current outside temperature, as well as the following traveler navigational information: average fuel economy, distance to empty (DTE), elapsed time (ET), and trip odometer (ODO). OPERATION: The information needed for the traveler functions is received over the CCD bus from the body control module. NOTE: If the compass mini-trip module has been replaced, it may be necessary to reset the calibration. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Adjustments > Setting Compass Variance Trip Computer: Adjustments Setting Compass Variance DEFINITION: Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the zone map below. The number shown for your area is the variance number for your area (continued on the following page). 1. Set the Compass/Mini-Trip Console (CMTC) to compass/temperature mode. 2. Press and hold down both the US/METRIC button and the STEP button for 5 seconds. NOTE: If the buttons are held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number and resume normal operation. NOTE: Do not attach any magnetic device such as a magnetic CB antenna to the vehicle. This can cause the compass to give false readings. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Adjustments > Setting Compass Variance > Page 7680 Trip Computer: Adjustments Setting the Compass The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank, the vehicle must be demagnetized. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly Body Controller: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 7691 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly Body Controller: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Controller: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 7697 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] > Component Information > Technical Service Bulletins > Page 7698 Body Control Module System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Body Controller: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7701 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7702 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7703 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7704 Body Controller: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7705 Body Controller: Connector Views Body Control Module Blue Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7706 Body Control Module Natural Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7707 BCM Natural Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7708 BCM Blue Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and ID > BCM Identification Body Controller: Application and ID BCM Identification There are two different body control modules available on these vehicles; One supports the mechanical instrument cluster as well as the electro/mechanical instrument cluster. - The other supports the electronic instrument cluster. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and ID > BCM Identification > Page 7711 Body Controller: Application and ID Glossary of Terms BCM - Body Control Module CCD - Chrysler Collision Detection (Vehicle Communications Bus) CMTC - Compass/mini-trip Computer (module) DLC - Data Link Connector (previously Called "Diagnostic Connector") DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument Cluster ET - Elapsed Time IOD - Ignition Off Draw MET - Metric MIC - Mechanical Instrument Cluster ODO - Odometer PCM - Powertrain Control Module PDC - Power Distribution Center RKE Remote Keyless Entry Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] > Component Information > Application and ID > Page 7712 Body Controller: Description and Operation PURPOSE The body control module: Provides power or ground for a variety of systems and uses a voltage drop to monitor these systems. - Is the only module that has the capability of providing both bias and termination on the CCD bus system. - Is used to store odometer information displayed in the electronic instrument cluster. OPERATION The body systems are monitored by individual control modules, which send information about their operation to the body control module over the CCD (Chrysler Collision Detection multiplex system) bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed to the appropriate module(s). - Each module receives the same information about a component or circuit as another module does. - This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. BODY SYSTEM COVERAGE: - Automatic Door Locks - Compass/mini-trip Module - Courtesy Lamps - Electronic Instrument Cluster (EIC) - Electro/mechanical Instrument Cluster - Mechanical Instrument Cluster (MIC) - Illuminated Entry - Remote Keyless Entry (RKE) - Intermittent Wipers - Liftgate Release NOTE: Communication over the CCD bus is essential to the proper operation of vehicle on-board diagnostic systems and scan tool communication. Bus or scan tool problems must be corrected before proceeding with diagnostic testing. If there is a problem, refer to Vehicle Communications (CCD) Bus/Testing and Inspection for diagnosis and repair procedures. TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is not set or if it is set incorrectly, any speed-related accessories will not operate or will operate inaccurately. - This includes the speedometer, speed control, rolling door locks, and other devices that are operated by the powertrain and body controllers. - For instructions on setting the pinion factor, see the appropriate transmission section. GLOSSARY OF TERMS BCM - Body Control Module CCD - Chrysler Collision Detection (vehicle Communications Bus) CMTC - Compass/mini-trip Computer (module) DLC - Data Link Connector (previously Called "diagnostic Connector") DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument Cluster ET - Elapsed Time IOD - Ignition Off Draw MET - Metric MIC - Mechanical Instrument Cluster ODO - Odometer PCM - Powertrain Control Module PDC - Power Distribution Center RKE Remote Keyless Entry Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Controller: Component Tests and General Diagnostics Diagnostic Notes - Read First TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is not set or if it is set incorrectly, any speed-related accessories will not operate or will operate inaccurately. - This includes the speedometer, speed control, rolling door locks, and other devices that are operated by the powertrain and body controllers. - For instructions on setting the pinion factor, see the appropriate transmission section. NOTE: These diagnostics are based on the failure condition or symptom being present at the time of diagnosis. TIPS: Verify that the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Be careful when performing electrical tests to prevent accidental shorting of terminals. Such mistakes can damage fuses or components and will sometimes set a second code, making diagnosis of the original problem more difficult. WARNINGS: - When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as watchbands or bracelets that might make an inadvertent electrical contact. - When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests. To efficiently diagnose CCD bus problems follow these six steps: 1. Verify Complaint 2. Check for Related Symptoms 3. Analyze Symptoms 4. Isolate the Problem 5. Repair the Isolated Problem 6. Verify Proper Operation ROAD TESTING Some complaints will require a test drive to duplicate the diagnostic code or symptom condition and to verify the repair. CAUTIONS: Before road testing a vehicle, be sure that all components are reassembled. - During the test drive, do not try to read the scan tool screen while in motion. - Do not hang the scan tool from the rear view mirror or operate it yourself. Have an assistant available to operate the scan tool. TIP: The pinion factor must be set for all new transmission control modules. If the pinion factor is not set or if it is set incorrectly, any speed-related accessories will not operate or will operate inaccurately. - This includes the speedometer, speed control, rolling door locks, and other devices that are operated by the powertrain and body controllers. - For instructions on setting the pinion factor, see the appropriate transmission section. Description of On-Board Diagnostics A scan tool is required to read body system trouble codes. However, not all body system problems have a corresponding trouble code. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 7715 Body Controller: Scan Tool Testing and Procedures If the scan tool Does Not Power Up; Check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). If all connections are proper between scan tool and the vehicle, and the vehicle battery is fully charged, an inoperative scan tool may be the result or faulty cable or vehicle wiring. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Controller <--> [Body Control Module] > Component Information > Testing and Inspection > Page 7716 Body Controller: Tools and Equipment The following tools are recommended to properly diagnose CCD bus problems: - Scan tool -- with correct cartridge and applicable connectors. - Jumper Wires - Ohmmeter - Oil Pressure Gauge - Voltmeter Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Cabin Ventilation Duct > Component Information > Technical Service Bulletins > Customer Interest for Cabin Ventilation Duct: > 235994 > Aug > 94 > Left B Post Exhauster - Loose Cabin Ventilation Duct: Customer Interest Left B Post Exhauster - Loose NO: 23-59-94 GROUP: Body DATE: Aug. 5, 1994 SUBJECT: Left "B"-Post Body Exhauster Retention MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager 1993 - 1994 (ES) Chrysler Voyager (European Market) SYMPTOM/CONDITION: The retention of the left "B"-post body exhauster on some vehicles may be inadequate. This may cause the "B"-post body exhauster to come out of the opening in the "B"-post on its own or with very little assistance. DIAGNOSIS: Inspect the left "B"-post for the presence or looseness of the "B"-post body exhauster. Perform the repair procedure if the exhauster is loose of missing. PARTS REQUIRED: AR 82300234 Sealant, RTV AR 4475320 Exhauster, Body REPAIR PROCEDURE: This bulletin involves adhering the "B"-post body exhauster to the "B"-post. 1. Remove the "B"-post body exhauster, or if necessary, obtain a new one, P/N 4475320. 2. Apply a 4 in. (100 mm) long 1/8 in. (3 mm) bead of RTV sealant, P/N 82300234, to both side flange surfaces of the "B"-post body exhauster that mate to the "B"-post (refer to illustration). 3. Install the "B"-post body exhauster into the opening in the "B"-post and press it into place. 4. Wipe the "B"-post body exhauster and the "B"-post clean of any excess RTV sealant that may have squeezed out from between the "B"-post body Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Cabin Ventilation Duct > Component Information > Technical Service Bulletins > Customer Interest for Cabin Ventilation Duct: > 235994 > Aug > 94 > Left B Post Exhauster - Loose > Page 7725 exhauster and the "B"-post. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-02-89-91 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Cabin Ventilation Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cabin Ventilation Duct: > 235994 > Aug > 94 > Left B Post Exhauster - Loose Cabin Ventilation Duct: All Technical Service Bulletins Left B Post Exhauster - Loose NO: 23-59-94 GROUP: Body DATE: Aug. 5, 1994 SUBJECT: Left "B"-Post Body Exhauster Retention MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager 1993 - 1994 (ES) Chrysler Voyager (European Market) SYMPTOM/CONDITION: The retention of the left "B"-post body exhauster on some vehicles may be inadequate. This may cause the "B"-post body exhauster to come out of the opening in the "B"-post on its own or with very little assistance. DIAGNOSIS: Inspect the left "B"-post for the presence or looseness of the "B"-post body exhauster. Perform the repair procedure if the exhauster is loose of missing. PARTS REQUIRED: AR 82300234 Sealant, RTV AR 4475320 Exhauster, Body REPAIR PROCEDURE: This bulletin involves adhering the "B"-post body exhauster to the "B"-post. 1. Remove the "B"-post body exhauster, or if necessary, obtain a new one, P/N 4475320. 2. Apply a 4 in. (100 mm) long 1/8 in. (3 mm) bead of RTV sealant, P/N 82300234, to both side flange surfaces of the "B"-post body exhauster that mate to the "B"-post (refer to illustration). 3. Install the "B"-post body exhauster into the opening in the "B"-post and press it into place. 4. Wipe the "B"-post body exhauster and the "B"-post clean of any excess RTV sealant that may have squeezed out from between the "B"-post body Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Cabin Ventilation Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cabin Ventilation Duct: > 235994 > Aug > 94 > Left B Post Exhauster - Loose > Page 7731 exhauster and the "B"-post. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-02-89-91 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Windshield/Cowl - Squeak Elimination Cowl: Technical Service Bulletins Windshield/Cowl - Squeak Elimination NO: 23-27-94 GROUP: Body DATE: Mar. 18, 1994 SUBJECT: Squeak Noise At The Base Of The Windshield MODELS: 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: Water soluble support spacers are used in the windshield installation process at the assembly plant to properly position the windshield. During the transit and vehicle predelivery processes, if enough water does not come in contact with the windshield support spacers, they may not dissolve as intended and may cause a squeaking noise. Typically, enough water contacts the windshield support spacers during a car wash. Prior to delivering the new vehicle to the customer, look for the support spacers at both sides of the base of the windshield (refer to the illustration). If the support spacers are still in place, raise the cowl and pry them out or slowly pour two gallons of hot water directly on them until they dissolve. This will prevent the customer from experiencing a squeak condition on the new vehicle. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > System Information > Service and Repair Front Door Handle: Service and Repair Outside Handle/Lock Cylinder 1. Remove door trim panel and water shield as necessary to gain access to outside door handle. 2. Disconnect lock cylinder linkage from door latch. 3. Disconnect latch release linkage from door latch. 4. Disconnect illuminated entry switch wire connector. 5. Remove nut holding outside handle retaining bracket to door panel and separate bracket from door. 6. Lift lock cylinder linkage upward to parallel back of outside handle. 7. Separate outside handle from door. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair Front Door Hinge: Service and Repair Front Door REMOVAL 1. Remove front fender wheelhouse splash shield. 2. Support door on a suitable lifting device. 3. Drive out hinge pin on the effected hinge. 4. Remove bolts holding hinge to hinge pillar and separate hinge form vehicle. INSTALLATION Reverse the preceding operation. Align door to achieve 6 mm (0.240 in.) gap to all surrounding panels and flush across gaps. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments Front Door Latch: Adjustments LATCH/LOCK CONTROL ADJUSTMENTS The lock knob, inside release handle and outside release handle can be adjusted when door latch components are replaced or do not operate properly. Lock Knob Adjuster LOCK KNOB ADJUSTMENT 1. Remove sliding door trim panel. 2. Release sliding door latch and slide the door open about 100 mm (4 in.). 3. Through elongated slot at the bottom of the control, loosen the socket head screw holding lock mechanism together. 4. Pull the lock link rod forward locking the latch. 5. Tighten socket head screw to hold lock mechanism together. 6. Test door lock operation 7. Install door trim panel. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments > Page 7748 Front Door Latch: Service and Repair Front Door Latch 1. Remove door trim panel and water shield as necessary to gain access to door latch. 2. Disconnect all linkage rods from latch. 3. Disconnect power door lock actuator wire connector. 4. Remove screws holding latch to door end frame. 5. Separate door latch from door. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair Front Door Panel: Service and Repair REMOVAL Front Door Trim 1. Lower the door glass. 2. If the vehicle is equipped with power windows, disconnect the battery negative cable. 3. Remove the screw holding the door latch handle bezel to the door trim panel. Remove the bezel from the door. 4. Remove the screw holding the upper door trim to the side view mirror frame. 5. Remove plugs and screws holding the trim to the door above the map pocket. 6. Remove the plug and screw that holds the bottom rear corner of the trim panel to the door. 7. Remove the plugs and screws holding the armrest to the trim panel. 8. Remove the window crank (if equipped with manual windows). 9. Disengage the trim clips that hold the trim panel to the perimeter door inner panel. 10. Lift trim panel upwards to disengage barb clips at top of trim panel. 11. Disconnect courtesy lamp, power window switch, power lock switch electrical connectors (if equipped). 12. Remove trim panel from door. INSTALLATION 1. Connect courtesy lamp, power window switch, power lock switch electrical connectors (if equipped). 2. Install trim panel by pushing in and down at the same time. Pushing down will engage the barb clips at the top of the trim panel. 3. Push the trim clips in at the perimeter of the door inner panel. 4. Install the window crank (if equipped with manual windows). 5. Install the screws and plugs that hold the armrest to the trim panel. 6. Install the screw and plug into the bottom rear corner of the trim panel. 7. Install the screws and plugs that hold the trim panel to the door above the map pocket. 8. Install the screw holding the upper door trim to the side view mirror frame. 9. Install the door latch handle bezel and its screw to the door trim panel. 10. Connect the negative battery cable if it was removed (if equipped with power windows). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Frame Rear Molding Front Door Weatherstrip: Service and Repair Front Door Frame Rear Molding Belt Moulding And Weatherstrip 1. Remove belt molding and weatherstrip as necessary to clear door frame molding removal path. 2. Remove glass run weatherstrip to gain access to molding clips. 3. Disengage clips holding door frame molding to door frame 4. Separate molding from door. 5. Reverse the preceding operation for installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Frame Rear Molding > Page 7756 Front Door Weatherstrip: Service and Repair Front Door Belt Molding and Weatherstrip VAN ONLY Belt Moulding And Weatherstrip 1. Remove door glass. 2. Remove side view mirror. 3. Remove screws holding belt molding and weatherstrip to door panel. 4. Separate belt molding and weatherstrip from door. 5. Reverse the preceding operation for installation. WAGON ONLY Belt Moulding And Weatherstrip 1. Remove door glass. 2. Remove side view mirror. 3. Remove door glass run weatherstrip. 4. Disengage clips holding door frame molding to door frame. 5. Remove screws holding belt molding and weatherstrip to door panel. 6. Separate belt molding and weatherstrip from door. 7. Reverse the preceding operation for installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair Glass Channel And Run Weatherstrip 1. Lower door glass to down position. 2. Remove side view mirror as necessary to gain clearance for weatherstrip removal. 3. Pull glass run weatherstrip from door frame channel. 4. Reverse the preceding operation for installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Adjustments > Sliding Side Door, Interior Handle Sliding Door Handle: Adjustments Sliding Side Door, Interior Handle Inside Release Handle Adjuster 1. Remove sliding door trim panel. 2. Release sliding door latch and slide the door open about 100 mm (4 in.). 3. Loosen socket head screw holding linkage bell crank together. 4. Using a screw driver through the elongated slot behind inside door handle, push linkage rearward to take up all free travel. 5. Tighten socket head screw to hold bell crank together. 6. Test inside door handle operation. 7. Install door trim panel. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Adjustments > Sliding Side Door, Interior Handle > Page 7766 Sliding Door Handle: Adjustments Sliding Side Door, Exterior Handle Outside Release Handle Adjuster 1. Remove sliding door trim panel. 2. Release sliding door latch and slide the door open about 100 mm (4 in.). 3. Loosen socket head screw holding central pivot cam together. 4. Hold central pivot against the outside door handle actuator button. 5. Tighten socket head screw to hold central pivot cam together. 6. Test outside door handle operation. 7. Install door trim panel. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Service and Repair > Interior Door Handle Sliding Door Handle: Service and Repair Interior Door Handle Inside Latch/Lock Control 1. Remove sliding door trim panel and water shield. 2. Remove screws holding inside door handle bezel to latch/lock control assembly. 3. Separate bezel from control. 4. Remove bolts holding latch/lock control to inner door panel. 5. Pull control away from inner door panel and disconnect linkage rods and power door lock wire connector, if equipped. 6. Separate control from door. 7. Reverse the preceding operation for installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Service and Repair > Interior Door Handle > Page 7769 Sliding Door Handle: Service and Repair Exterior Door Handle Sliding Door Outside Release Handle 1. Remove sliding door trim panel and water shield. 2. Remove screws holding inside latch/lock control assembly to door inner panel. 3. Disconnect linkage rods and wire connectors as necessary to gain access to outside handle mounting. 4. Disconnect lock rod from lock cylinder arm. 5. Remove nuts holding mounting plate to inner door panel and separate plate from door. 6. Separate outside handle from door. 7. Reverse the preceding operation for installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Interior Trim Panel > Component Information > Service and Repair Sliding Door Interior Trim Panel: Service and Repair REMOVAL Sliding Door Trim Panel 1. Close the sliding door. 2. Remove the plug and screw at the rearward center of door trim panel. 3. Remove the hidden screw from the upper rearward corner of the carpet insert. 4. Remove the screws along the bottom of the trim panel used to hold the trim panel to the door. 5. Disengage the trim clips holding the trim panel to the door. These are located around the perimeter of the door. 6. Lift up on the trim panel to disengage the barb clips at the top of the trim panel. 7. Remove the trim panel. INSTALLATION 1. Install the trim panel by pushing in and down at the same time (this is done to snap the barb clips into place at the top of the trim panel). 2. Install the trim clips around the perimeter of the door. 3. Install the screws along the bottom of the trim panel that hold the trim panel to the door. 4. Install the hidden screw behind the upper rearward corner of the carpet insert. 5. Install the screw and plug at the rearward center of the door trim panel (this screw should be installed just under the rear of the sliding door window). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Service and Repair Sliding Door Latch: Service and Repair Sliding Door Latch/Lock Linkage SLIDING DOOR LATCH/LOCK LINKAGE REMOVAL 1. Remove sliding door trim panel and water shield. 2. Remove latch/lock control. 3. Disconnect ends of linkage rod to be replaced. 4. Separate linkage rod from door. SLIDING DOOR LATCH/LOCK LINKAGE INSTALLATION Reverse the preceding operation. Sliding Door Rear Latch SLIDING DOOR REAR LATCH REMOVAL 1. Remove sliding door trim panel and water shield as necessary. 2. Unlatch door and allow to swing outward, do not open. 3. Disconnect linkage rods from rear latch. 4. Remove screws holding latch to door end frame. 5. Separate latch from door end frame and remove through access hole in inner door panel. SLIDING DOOR REAR LATCH INSTALLATION Reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Release Cable > Component Information > Service and Repair Fuel Door Release Cable: Service and Repair Fuel Door Remote Cable 1. Remove interior trim as necessary to gain access to cable. 2. Remove screw holding hood release handle to mechanism. Separate handle from mechanism. 3. Remove screws holding release mechanism to seat riser. Separate mechanism from riser. 4. Disengage cable casing from slot on mechanism. 5. Remove nut holding cable end to fuel fill opening. 6. Remove cable from vehicle. 7. Reverse the preceding operation for installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Description and Operation Power Trunk / Liftgate Lock Actuator: Description and Operation Liftgate Release - This option has a button located on the left side of the instrument panel. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair Trunk / Liftgate Latch: Service and Repair Lift Gate Latch 1. Raise lift gate to open position. 2. Remove lift gate trim panel. 3. Disconnect linkage rods from latch. 4. Remove screws holding latch to lift gate. 5. Separate latch from lift gate. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations > Page 7790 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Lower Side Moulding / Trim: > 237794 > Oct > 94 > Body Cladding - Interferes With Use Of Jack Lower Side Moulding / Trim: Customer Interest Body Cladding - Interferes With Use Of Jack NO: 23-77-94 GROUP: Body DATE: Oct. 28, 1994 SUBJECT: Body Cladding Interferes With Use Of Jack MODELS: 1994 - 1995 (AS) Caravan SYMPTOM/CONDITION: Difficulty engaging the front jack locating pins on the lower sill of the body due to interference with the flange of the body cladding on some LE and ES Caravan models. DIAGNOSIS: Visually inspect for adequate clearance for the jack to engage the front locating pins. If additional clearance is needed, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves creating a notch in the body side cladding. 1. Raise the vehicle on an appropriate lifting device. 2. Cut out the template illustrated above. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Lower Side Moulding / Trim: > 237794 > Oct > 94 > Body Cladding - Interferes With Use Of Jack > Page 7803 3. Position the template on the bottom flange of the cladding so the notch of the template is centered with the front jack locating pin on the vehicle. Mark the cladding for the notch and the centers for the two 3/8" holes. 4. Drill 1/8" pilot holes at each hole center location, then drill hole to 3/8". 5. Use a utility knife or shears to make the straight cuts for the notch so they intersect the edges of the holes drilled in step 4. 6. Repeat steps 3 through 5 for the other side. 7. Lower vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-02-38-91 0.4 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lower Side Moulding / Trim: > 237794 > Oct > 94 > Body Cladding - Interferes With Use Of Jack Lower Side Moulding / Trim: All Technical Service Bulletins Body Cladding - Interferes With Use Of Jack NO: 23-77-94 GROUP: Body DATE: Oct. 28, 1994 SUBJECT: Body Cladding Interferes With Use Of Jack MODELS: 1994 - 1995 (AS) Caravan SYMPTOM/CONDITION: Difficulty engaging the front jack locating pins on the lower sill of the body due to interference with the flange of the body cladding on some LE and ES Caravan models. DIAGNOSIS: Visually inspect for adequate clearance for the jack to engage the front locating pins. If additional clearance is needed, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves creating a notch in the body side cladding. 1. Raise the vehicle on an appropriate lifting device. 2. Cut out the template illustrated above. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lower Side Moulding / Trim: > 237794 > Oct > 94 > Body Cladding - Interferes With Use Of Jack > Page 7809 3. Position the template on the bottom flange of the cladding so the notch of the template is centered with the front jack locating pin on the vehicle. Mark the cladding for the notch and the centers for the two 3/8" holes. 4. Drill 1/8" pilot holes at each hole center location, then drill hole to 3/8". 5. Use a utility knife or shears to make the straight cuts for the notch so they intersect the edges of the holes drilled in step 4. 6. Repeat steps 3 through 5 for the other side. 7. Lower vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-02-38-91 0.4 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 220794 > Oct > 94 > Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left Cross-Member: Customer Interest Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left NO: 22-07-94 GROUP: Tires and Wheels DATE: Oct. 21, 1994 SUBJECT: Tire Leads/Drifts Left THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-04-93 DATED JUN. 11, 1993 WHICH SHOULD BE NOTED IN YOUR FILES AND THE 1993 TECHNICAL SERVICE BULLETINS MANUAL (PUBLICATION NO. 81-699-94000). THIS REVISION INCLUDES ADDING 1994 AND 1995 MODEL VEHICLES, ADDS STEP 8 AND CHANGES THE FAILURE CODE. ALL REVISIONS ARE HIGHLIGHTED AND WITH **ASTERISKS**. MODELS: 1991 - **1995** (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Some vehicles may exhibit a tendency to drift left. Road surfaces have significant effect on drift tendencies. DIAGNOSIS: Test drive the vehicle on a road surface that slopes down to the right. On lanes that slope down to the right, the vehicle should track with little or no drift. On lanes that slope down to the left, a slight drift to the left is expected and normal. If the vehicle exhibits a tendency to drift left while in lanes that slope to the right, the following diagnostic procedures should be followed: A. Cross switch the front tire/wheel assemblies and re-evaluate the vehicle. If the drift is corrected, return the vehicle to the customer. If the drift to the left becomes worse, return the tire/wheel assemblies to their original positions and perform step B of the diagnosis. If the drift to the left is unchanged, perform step B of the diagnosis. B. Check and adjust as necessary, the front alignment to the following preferred specifications: Camber: 0.3 degree positive Toe: 0.1 degree in. If the vehicle still drifts left while in lanes that slope to the right, perform the repair procedure. PARTS REQUIRED: 1 6502553 Screw and Washer Assembly REPAIR PROCEDURE: This bulletin involves repositioning the front crossmember. 1. Raise the vehicle on a hoist that leaves the front wheels unsupported. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 220794 > Oct > 94 > Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left > Page 7819 2. Remove the left rear nut and shouldered stud attaching the front crossmember to the frame structure (Refer to the Illustration). 3. Install and finger tighten screw and washer assembly, P/N 6502553, at the left rear attachment position of the front crossmember. 4. Loosen the two front and right rear front crossmember attachments. 5. Using an appropriate pry bar at the left side of the front crossmember, rotate the front crossmember assembly forward using the right rear attachment as the pivot point for the rotation (looking at the front crossmember from underneath the vehicle, this will be a counterclockwise rotation). Rotate the crossmember until it contacts the left rear crossmember fastener. 6. Torque the four front crossmember fasteners to 110 ft.lbs. while the crossmember's position is held against the left rear fastener. 7. Check and adjust as necessary, the front alignment to the following preferred specifications: Camber: 0.3 degree positive Toe: 0.1 degree in. **8. If the vehicle still exhibits a left lead condition, contact your zone office for further assistance.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 02-00-01-95 (Includes Alignment) 1.0 Hrs. FAILURE CODE: **LL - Leads Left** Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 220794 > Oct > 94 > Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left Cross-Member: All Technical Service Bulletins Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left NO: 22-07-94 GROUP: Tires and Wheels DATE: Oct. 21, 1994 SUBJECT: Tire Leads/Drifts Left THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-04-93 DATED JUN. 11, 1993 WHICH SHOULD BE NOTED IN YOUR FILES AND THE 1993 TECHNICAL SERVICE BULLETINS MANUAL (PUBLICATION NO. 81-699-94000). THIS REVISION INCLUDES ADDING 1994 AND 1995 MODEL VEHICLES, ADDS STEP 8 AND CHANGES THE FAILURE CODE. ALL REVISIONS ARE HIGHLIGHTED AND WITH **ASTERISKS**. MODELS: 1991 - **1995** (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Some vehicles may exhibit a tendency to drift left. Road surfaces have significant effect on drift tendencies. DIAGNOSIS: Test drive the vehicle on a road surface that slopes down to the right. On lanes that slope down to the right, the vehicle should track with little or no drift. On lanes that slope down to the left, a slight drift to the left is expected and normal. If the vehicle exhibits a tendency to drift left while in lanes that slope to the right, the following diagnostic procedures should be followed: A. Cross switch the front tire/wheel assemblies and re-evaluate the vehicle. If the drift is corrected, return the vehicle to the customer. If the drift to the left becomes worse, return the tire/wheel assemblies to their original positions and perform step B of the diagnosis. If the drift to the left is unchanged, perform step B of the diagnosis. B. Check and adjust as necessary, the front alignment to the following preferred specifications: Camber: 0.3 degree positive Toe: 0.1 degree in. If the vehicle still drifts left while in lanes that slope to the right, perform the repair procedure. PARTS REQUIRED: 1 6502553 Screw and Washer Assembly REPAIR PROCEDURE: This bulletin involves repositioning the front crossmember. 1. Raise the vehicle on a hoist that leaves the front wheels unsupported. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 220794 > Oct > 94 > Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left > Page 7825 2. Remove the left rear nut and shouldered stud attaching the front crossmember to the frame structure (Refer to the Illustration). 3. Install and finger tighten screw and washer assembly, P/N 6502553, at the left rear attachment position of the front crossmember. 4. Loosen the two front and right rear front crossmember attachments. 5. Using an appropriate pry bar at the left side of the front crossmember, rotate the front crossmember assembly forward using the right rear attachment as the pivot point for the rotation (looking at the front crossmember from underneath the vehicle, this will be a counterclockwise rotation). Rotate the crossmember until it contacts the left rear crossmember fastener. 6. Torque the four front crossmember fasteners to 110 ft.lbs. while the crossmember's position is held against the left rear fastener. 7. Check and adjust as necessary, the front alignment to the following preferred specifications: Camber: 0.3 degree positive Toe: 0.1 degree in. **8. If the vehicle still exhibits a left lead condition, contact your zone office for further assistance.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 02-00-01-95 (Includes Alignment) 1.0 Hrs. FAILURE CODE: **LL - Leads Left** Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair Carpet: Service and Repair Floor Carpet And Silencers 1. Remove full forward console, if equipped. 2. Remove Seats. 3. Remove door sill scuff plates. 4. Remove rear seat anchor well bezels, if equipped. 5. Fold carpet to center of vehicle and remove through sliding door. 6. Reverse the preceding operation for installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions Console Lamp: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7835 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7836 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7837 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7838 Console Lamp: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7839 Console Lamp: Electrical Diagrams Headlamp Switch Controlled Interior & Console Lamps (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7840 Headlamp Switch Controlled Interior & Console Lamps (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least ten minutes after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 7846 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming ARMING 1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate SRS system is functioning correctly. 5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air Bag Systems/Testing and Inspection. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Headliner - Fastener Pins Headliner: Technical Service Bulletins Headliner - Fastener Pins NO: 23-20-94 GROUP: Body DATE: Feb. 25, 1994 SUBJECT: Headliner Fastener Pins MODELS: 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: A new style of headliner fastener pin will be used on the subject vehicles beginning 3/21/94 (MDH 0321XX). The new pins will require replacement any time they are removed because of damage to the original pins caused during removal. Part numbers for replacement pins are listed below: AR JB66PB7 Blue AR JB66PD5 Quartz AR JB66PF6 Driftwood AR JB66PM6 Red These parts numbers are for the old style pins and will be superseded by the new style pin in approximately 30 days. The new style pins provide greater retention than the old style and should be used if difficulty in keeping the pin(s) in place is experienced. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Page 7851 Headliner: Service and Repair Headliner 1. Remove overhead console, if equipped. 2. Remove inboard sun visor clips, if equipped. 3. Remove roof rail moldings as necessary to gain clearance for head lining removal. 4. Remove sliding door upper track cover. 5. Remove right quarter trim panel. 6. Remove dome lamp, if equipped. 7. Separate head lining from vehicle. 8. Reverse the preceding operation for installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical Service Bulletins > Customer Interest: > 230394 > Jan > 94 > Middle Bench Seat Outer Seatbelt - High Extension Effort Trim Panel: Customer Interest Middle Bench Seat Outer Seatbelt - High Extension Effort NO: 23-03-94 GROUP: Body DATE: Jan. 21, 1994 SUBJECT: Middle Bench Seat Left Seat Belt MODELS: 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO SHORT WHEEL BASE (SWB) VEHICLES. SYMPTOM/CONDITION: High effort is required to extend the middle bench seat left seat belt or the seat belt will not return to the stowed position. DIAGNOSIS: Extend the seat belt. If high effort is required or the seat belt will not return, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves trimming the silencer pad on the back side of the left upper quarter trim panel. 1. Using the procedure outlined (steps 1-4) on Page 23-39 of the 1994 Town & Country/Caravan/Voyager Service Manual (Publication No. 81-370-4105) remove the left quarter trim insert. 2. Remove the silencer material from the back side of the upper quarter trim panel from the area shown in the illustration. 3. Reverse the procedure in step 1 to reinstall the interior trim. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 23-20-56-91 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trim Panel: > 235394 > Jul > 94 > Lift Gate Trim Panel - Cracked Trim Panel: All Technical Service Bulletins Lift Gate Trim Panel - Cracked NO: 23-53-94 GROUP: Body DATE: Jul. 8, 1994 SUBJECT: Liftgate Trim Panel Cracking MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: A new type of screw is being used during vehicle assembly to attach the liftgate trim panel to the top of the liftgate beginning the week of 6/27/94. These screws are undercut between the bottom of the head and the threads of the screw. This style of screw will act as though it is stripped when it is installed. When removing these screws, the trim panel must be pulled back/away slightly from the liftgate in order for the threads of the screws to engage the sheetmetal of the liftgate so the screws can then be screwed out. These screws provide the proper retention of the trim panel while preventing over tightening of the screws that leads to cracks in the liftgate trim panel. NOTE: WHENEVER A LIFTGATE TRIM PANEL IS REPLACED, ESPECIALLY BECAUSE OF CRACKING, ALWAYS USE THE NEW STYLE SCREWS (P/N 6035556). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trim Panel: > 230394 > Jan > 94 > Middle Bench Seat Outer Seatbelt - High Extension Effort Trim Panel: All Technical Service Bulletins Middle Bench Seat Outer Seatbelt - High Extension Effort NO: 23-03-94 GROUP: Body DATE: Jan. 21, 1994 SUBJECT: Middle Bench Seat Left Seat Belt MODELS: 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO SHORT WHEEL BASE (SWB) VEHICLES. SYMPTOM/CONDITION: High effort is required to extend the middle bench seat left seat belt or the seat belt will not return to the stowed position. DIAGNOSIS: Extend the seat belt. If high effort is required or the seat belt will not return, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves trimming the silencer pad on the back side of the left upper quarter trim panel. 1. Using the procedure outlined (steps 1-4) on Page 23-39 of the 1994 Town & Country/Caravan/Voyager Service Manual (Publication No. 81-370-4105) remove the left quarter trim insert. 2. Remove the silencer material from the back side of the upper quarter trim panel from the area shown in the illustration. 3. Reverse the procedure in step 1 to reinstall the interior trim. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 23-20-56-91 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trim Panel: > 235394 > Jul > 94 > Lift Gate Trim Panel - Cracked Trim Panel: All Technical Service Bulletins Lift Gate Trim Panel - Cracked NO: 23-53-94 GROUP: Body DATE: Jul. 8, 1994 SUBJECT: Liftgate Trim Panel Cracking MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: A new type of screw is being used during vehicle assembly to attach the liftgate trim panel to the top of the liftgate beginning the week of 6/27/94. These screws are undercut between the bottom of the head and the threads of the screw. This style of screw will act as though it is stripped when it is installed. When removing these screws, the trim panel must be pulled back/away slightly from the liftgate in order for the threads of the screws to engage the sheetmetal of the liftgate so the screws can then be screwed out. These screws provide the proper retention of the trim panel while preventing over tightening of the screws that leads to cracks in the liftgate trim panel. NOTE: WHENEVER A LIFTGATE TRIM PANEL IS REPLACED, ESPECIALLY BECAUSE OF CRACKING, ALWAYS USE THE NEW STYLE SCREWS (P/N 6035556). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar and Roof Rail Moldings Trim Panel: Service and Repair A-Pillar and Roof Rail Moldings Interior Trim 1. Remove grab handle, if equipped. 2. Remove windshield side garnish molding. 3. Remove plug and screw holding A-pillar trim to roof rail. 4. Disengage fasteners holding A-pillar trim to A-pillar. 5. Separate A-pillar trim from vehicle. 6. Reverse the preceding operation for installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar and Roof Rail Moldings > Page 7876 Trim Panel: Service and Repair Left Quarter Trim Panel Quarter Trim Panel Quarter Trim Panel With Rear A/C 1. Remove ash tray. 2. Remove screw holding quarter trim insert to quarter trim from inside ash tray opening. 3. Pull outward at bottom of trim insert to disengage clips holding insert to quarter trim. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar and Roof Rail Moldings > Page 7877 4. Lift insert upward and separate quarter trim insert from vehicle. 5. Remove screws holding lower quarter trim panel to inner quarter panel. 6. Separate lower quarter trim from vehicle. 7. Remove covers and bolts holding shoulder harness turning loops to upper quarter panel. 8. Remove bolts holding outboard seat belt anchor to floor. 9. Remove seat belt retractor covers. 10. Remove screw holding coat hook to quarter panel. 11. Remove screws holding upper quarter trim panel to inner quarter panel. 12. Separate upper quarter trim panel from vehicle. 13. Reverse the preceding operation for installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar and Roof Rail Moldings > Page 7878 Trim Panel: Service and Repair Lift Gate Trim Panel Lift Gate Trim Panel REMOVAL 1. Raise lift gate and remove courtesy lamp lenses. 2. Remove courtesy lamp assemblies. Insert courtesy lamps through openings in the trim panel into lift gate, if equipped. 3. Remove speaker grilles, if equipped. 4. Remove plugs at the ends of the assist handle, and remove screws. Separate handle from trim panel, if equipped. 5. Remove push-in fasteners from above the rear window. 6. Remove two trim plugs at lower corners of trim panel and remove screws. 7. Disengage frog-leg fasteners around perimeter of trim panel. Separate trim panel from lift gate. INSTALLATION 1. Position trim panel under lift gate between the prop-rod cylinders. Insert courtesy lamp assemblies through trim cover openings. 2. Position frog-leg fasteners below holes in lift gate, one at a time, push (do not pound) fasteners into locked position. 3. Install assist handle, courtesy lamps, outer corner attaching screws, speaker grilles and push-in fasteners above rear window. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar and Roof Rail Moldings > Page 7879 Trim Panel: Service and Repair Right B-Pillar Trim Cover Interior Trim 1. Remove cover and bolt holding shoulder harness turning loop to B-pillar. 2. Remove bolt holding outboard seat belt anchor to floor. 3. Remove A-pillar trim as necessary to gain clearance for removal of B-pillar trim. 4. Remove door sill scuff plates to gain clearance for removal of B-pillar trim. 5. Remove screws holding B-pillar trim to B-pillar. 6. Separate B-pillar trim from vehicle 7. Reverse the preceding operation for installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar and Roof Rail Moldings > Page 7880 Trim Panel: Service and Repair A-Pillar and Roof Rail Moldings Interior Trim 1. Remove grab handle, if equipped. 2. Remove windshield side garnish molding. 3. Remove plug and screw holding A-pillar trim to roof rail. 4. Disengage fasteners holding A-pillar trim to A-pillar. 5. Separate A-pillar trim from vehicle. 6. Reverse the preceding operation for installation. Left Quarter Trim Panel Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar and Roof Rail Moldings > Page 7881 Quarter Trim Panel Quarter Trim Panel With Rear A/C 1. Remove ash tray. 2. Remove screw holding quarter trim insert to quarter trim from inside ash tray opening. 3. Pull outward at bottom of trim insert to disengage clips holding insert to quarter trim. 4. Lift insert upward and separate quarter trim insert from vehicle. 5. Remove screws holding lower quarter trim panel to inner quarter panel. 6. Separate lower quarter trim from vehicle. 7. Remove covers and bolts holding shoulder harness turning loops to upper quarter panel. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar and Roof Rail Moldings > Page 7882 8. Remove bolts holding outboard seat belt anchor to floor. 9. Remove seat belt retractor covers. 10. Remove screw holding coat hook to quarter panel. 11. Remove screws holding upper quarter trim panel to inner quarter panel. 12. Separate upper quarter trim panel from vehicle. 13. Reverse the preceding operation for installation. Lift Gate Trim Panel Lift Gate Trim Panel REMOVAL 1. Raise lift gate and remove courtesy lamp lenses. 2. Remove courtesy lamp assemblies. Insert courtesy lamps through openings in the trim panel into lift gate, if equipped. 3. Remove speaker grilles, if equipped. 4. Remove plugs at the ends of the assist handle, and remove screws. Separate handle from trim panel, if equipped. 5. Remove push-in fasteners from above the rear window. 6. Remove two trim plugs at lower corners of trim panel and remove screws. 7. Disengage frog-leg fasteners around perimeter of trim panel. Separate trim panel from lift gate. INSTALLATION 1. Position trim panel under lift gate between the prop-rod cylinders. Insert courtesy lamp assemblies through trim cover openings. 2. Position frog-leg fasteners below holes in lift gate, one at a time, push (do not pound) fasteners into locked position. 3. Install assist handle, courtesy lamps, outer corner attaching screws, speaker grilles and push-in fasteners above rear window. Right B-Pillar Trim Cover Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar and Roof Rail Moldings > Page 7883 Interior Trim 1. Remove cover and bolt holding shoulder harness turning loop to B-pillar. 2. Remove bolt holding outboard seat belt anchor to floor. 3. Remove A-pillar trim as necessary to gain clearance for removal of B-pillar trim. 4. Remove door sill scuff plates to gain clearance for removal of B-pillar trim. 5. Remove screws holding B-pillar trim to B-pillar. 6. Separate B-pillar trim from vehicle 7. Reverse the preceding operation for installation. Right Quarter Trim Panel Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar and Roof Rail Moldings > Page 7884 Interior Trim 1. Remove lift gate and sliding door sill scuff plate. 2. Remove sliding door upper track cover. 3. Pull outward at bottom of quarter trim insert to disengage fasteners holding insert to trim panel. 4. Lift upward on quarter trim insert and separate insert from quarter trim panel. 5. Remove screw holding coat hook to roof rail and separate hook from vehicle. 6. Remove covers and bolts holding shoulder harness turning lops to roof rail and separate belts from trim panel. 7. Remove bolts holding outboard seat belt to floor and separate belt from floor. 8. Remove plugs and screws holding quarter trim to inner quarter panel. 9. Separate quarter trim panel from vehicle. 10. Reverse the preceding operation for installation. Upper Track Cover Removal Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar and Roof Rail Moldings > Page 7885 Interior Trim 1. Remove plugs and screws holding upper track cover to sliding door track. 2. Separate track cover from vehicle. 3. Reverse the preceding operation for installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > Customer Interest for Jack: > 237794 > Oct > 94 > Body Cladding - Interferes With Use Of Jack Jack: Customer Interest Body Cladding - Interferes With Use Of Jack NO: 23-77-94 GROUP: Body DATE: Oct. 28, 1994 SUBJECT: Body Cladding Interferes With Use Of Jack MODELS: 1994 - 1995 (AS) Caravan SYMPTOM/CONDITION: Difficulty engaging the front jack locating pins on the lower sill of the body due to interference with the flange of the body cladding on some LE and ES Caravan models. DIAGNOSIS: Visually inspect for adequate clearance for the jack to engage the front locating pins. If additional clearance is needed, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves creating a notch in the body side cladding. 1. Raise the vehicle on an appropriate lifting device. 2. Cut out the template illustrated above. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > Customer Interest for Jack: > 237794 > Oct > 94 > Body Cladding - Interferes With Use Of Jack > Page 7894 3. Position the template on the bottom flange of the cladding so the notch of the template is centered with the front jack locating pin on the vehicle. Mark the cladding for the notch and the centers for the two 3/8" holes. 4. Drill 1/8" pilot holes at each hole center location, then drill hole to 3/8". 5. Use a utility knife or shears to make the straight cuts for the notch so they intersect the edges of the holes drilled in step 4. 6. Repeat steps 3 through 5 for the other side. 7. Lower vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-02-38-91 0.4 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Jack: > 237794 > Oct > 94 > Body Cladding - Interferes With Use Of Jack Jack: All Technical Service Bulletins Body Cladding - Interferes With Use Of Jack NO: 23-77-94 GROUP: Body DATE: Oct. 28, 1994 SUBJECT: Body Cladding Interferes With Use Of Jack MODELS: 1994 - 1995 (AS) Caravan SYMPTOM/CONDITION: Difficulty engaging the front jack locating pins on the lower sill of the body due to interference with the flange of the body cladding on some LE and ES Caravan models. DIAGNOSIS: Visually inspect for adequate clearance for the jack to engage the front locating pins. If additional clearance is needed, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves creating a notch in the body side cladding. 1. Raise the vehicle on an appropriate lifting device. 2. Cut out the template illustrated above. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Jack > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Jack: > 237794 > Oct > 94 > Body Cladding - Interferes With Use Of Jack > Page 7900 3. Position the template on the bottom flange of the cladding so the notch of the template is centered with the front jack locating pin on the vehicle. Mark the cladding for the notch and the centers for the two 3/8" holes. 4. Drill 1/8" pilot holes at each hole center location, then drill hole to 3/8". 5. Use a utility knife or shears to make the straight cuts for the notch so they intersect the edges of the holes drilled in step 4. 6. Repeat steps 3 through 5 for the other side. 7. Lower vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-02-38-91 0.4 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations Body Control Module System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7906 Keyless Entry Module: Diagrams Remote Keyless Entry Module Connectors Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Programming Module Keyless Entry Module: Service and Repair Programming Module PROGRAMMING RKE MODULE The RKE module is capable of retaining up to 4 different VAC(s) when vehicle battery power is interrupted. Replacement or additional key fob transmitter VAC(s) (maximum 4) can be programmed into the Body Control Module (BCM). A functional key fob transmitter is required to program the BCM to accept the new VAC. If a functional key fob transmitter is not available, a scan tool (DRB) can be used to program the BCM. (1) Using a functional key fob, unlock the vehicle and disarm the Vehicle Theft Alarm (2) Insert ignition key into the ignition switch. (3) Switch ignition to RUN position without starting engine. (4) On a functional key fob, actuate and hold the UNLOCK button for a minimum four seconds (maximum ten seconds). (5) While holding UNLOCK button, and before ten seconds passes, actuate and release the PANIC button. A single chime will sound to verify that the RKE module is set to receive the new VAC. (6) Within 30 seconds of the chime, actuate any key on each new key fob transmitter. After 30 seconds or when ignition switch is turned OF{ the RKE module will end the programming mode. A single chime will sound to verify that the RKE module will no longer receive additional VAC(s). (7) When VAC programming is complete, turn OFF ignition switch and verify RKE system operation using each key fob. NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror systems. If a primary key fob is being replaced, the memory seat and mirror module will require programming. Refer to Group 8R, Power Seats for proper (data link) programming procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Programming Module > Page 7909 Keyless Entry Module: Service and Repair Remote Keyless Entry Module Replacement REMOVAL (1) Remove instrument panel top cover. (2) Remove screws holding RKE module to instrument panel. (3) Disconnect wire connector from RKE module. (4) Remove module. INSTALLATION Reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Remote Keyless Entry - Transmitter Malfunction Keyless Entry Transmitter: Technical Service Bulletins Remote Keyless Entry - Transmitter Malfunction NO.: 08-51-93 GROUP: Electrical DATE: Oct. 15, 1993 SUBJECT: Remote Keyless Entry System MODELS: 1994 (AS) Caravan/Grand Caravan/Caravan CV Voyager/Grand Voyager/Town & Country SYMPTOM/CONDITION: Some vehicles may require the Remote Keyless Entry (RKE) transmitter button(s) to be repeatedly depressed to obtain a response from the system. NOTE: AS-BODY VEHICLES RESPOND DIFFERENTLY TO RKE INPUTS WHEN COMPARED TO THE SIMILAR SYSTEM USED PREVIOUSLY ON AC/AY-BODY VEHICLES. AS-BODY VEHICLES HAVE A SHORT DELAY AFTER A RKE TRANSMITTER BUTTON IS DEPRESSED BEFORE EITHER THE ILLUMINATED ENTRY OR HORN CHIRP IS ACTIVATED. THIS DELAY IS NORMAL FOR AS-BODY VEHICLES BUT DID NOT OCCUR ON PREVIOUS AC/AY-BODY VEHICLES. DIAGNOSIS: Open the transmitter case to access the batteries. If a white pentastar is NOT readily visible on the printed circuit board, perform the repair procedure. If the printed circuit board has a white pentastar, this TSB does not apply and the procedure outlined beginning on page 214 of the Body Diagnostic Procedures Manual (Publication No. 81- 699-0442) should be used. PARTS REQUIRED: 2 Transmitter 4469341 REPAIR PROCEDURE: This bulletin involves replacing the RKE transmitters. 1. Obtain two new transmitters (P/N 4469341) and verify they have a white pentastar on their printed circuit boards. 2. Using the procedure outlined on page 8P-5 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105) program the RKE transmitters. NOTE: IN THE SPIRIT OF CUSTOMER ONE, AND IN CASE THEY WERE NOT TOLD AT THE TIME OF DELIVERY, THIS WOULD BE AN EXCELLENT TIME TO ADVISE THE CUSTOMER THE HORN CHIRP FEATURE CAN BE CANCELED WHEN THE NEW RKE TRANSMITTERS ARE PROGRAMMED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-28-90 0.2 Hrs. FAILURE CODE: 58 - Internal Defect Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Page 7914 Keyless Entry Transmitter: Description and Operation Normal operation range is up to about a distance of 7 meters (23 ft.) of the vehicle. Range may be better or worse depending on the environment around the vehicle. Closeness to a radio frequency transmitter such as a radio station tower may degrade operational range, while range in an open field will be enhanced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Transmitter Programming Keyless Entry Transmitter: Service and Repair Transmitter Programming PROGRAM REMOTE KEYLESS ENTRY - Open and lower glove box door. - Locate program line a dark green wire with a molded insulator on the end. Located behind and lower end of the glove box. - Turn ignition switch to the ON position. - Connect the program line from the Remote Keyless Entry Module to ground. the door locks will lock and unlock to indicate the receiver is ready to receive transmitter code. Liftgate solenoid will not cycle. - Press any button on the transmitter to set code. If there is a second transmitter it has to be set at this time. The locks will cycle to confirm programming. - Disconnect the program line from ground. This returns the system to its normal operation mode. - Install glove box to original position. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Transmitter Programming > Page 7917 Keyless Entry Transmitter: Service and Repair Battery Replacement The batteries can be removed without special tools and are readily available at local retail stores. The recommended battery is Duracell DL 2016 or equivalent. Battery life is about one to two years. CAUTION: Do not touch the battery terminals or handle the batteries any more than necessary. Hands must be clean dry. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Motor <--> [Power Door Lock Actuator] > Component Information > Service and Repair Power Door Lock Motor: Service and Repair 1. Remove sliding door latch/lock control assembly. 2. Disconnect linkage rod from power door lock actuator. 3. Remove screws holding actuator to control. 4. Separate actuator from control. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations Power Door Lock Relay: Locations Micro Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 7925 Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions Mirrors: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 7930 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 7931 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 7932 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 7933 Mirrors: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 7934 Mirrors: Electrical Diagrams Power Remote Mirrors (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 7935 Power Remote Mirrors (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Service and Repair > Inside Rear View Mirror Mirrors: Service and Repair Inside Rear View Mirror Rear View Mirror 1. Using a wax pencil, locate and mark the mounting position of the button on the outside of the windshield. 2. If the vinyl pad had remained on the windshield glass, apply "low heat" to it with an electric heat gun until the vinyl softens; then peel the vinyl pad from the glass. 3. Thoroughly clean the inner surface of the windshield glass in the mounting area of the mirror button using a mild abrasive cleaning powder such as Ajax, Comet, or equivalent, on a clean cloth saturated with alcohol. Then, apply alcohol to a paper towel and wipe off any traces of remaining cleaner. 4. Thoroughly sand the windshield mounting surface (the side with least surface area) of the mirror button with a clean piece of fine grit sandpaper and wipe the surface clean with a clean paper towel saturated with alcohol. 5. Using kit 4054099 or equivalent, crush the vial in the plastic housing of the accelerator. This saturates the felt applicator. Remove paper sleeve. Apply a generous amount of accelerator on the mounting surface of the mirror button. 6. Allow the accelerator to dry for 5 minutes. Do not touch the mounting surface of the button or glass. 7. Apply a thin film of Accelerator to the inner surface of the windshield in the button mounting area. Allow one minute to dry. Do not touch the surface. 8. Apply one drop of Adhesive to the center of the windshield mounting surface of the mirror button and, using the bottom of the Adhesive tube, quickly distribute the adhesive evenly over the entire bonding surface of the button. 9. Position the bottom straight edge of the mirror button on the horizontal line and center it on the vertical line and press it firmly to the glass and apply pressure for about one minute. Proper location is essential as cement sets up very fast. 10. Allow five minutes for the adhesive to set; then, remove any excess adhesive residue from the windshield in the attachment area using an alcohol-dampened cloth. 11. Slide the mirror downward onto the button and tighten the screw. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Mirrors > Component Information > Service and Repair > Inside Rear View Mirror > Page 7938 Mirrors: Service and Repair Outside Rear View Mirror Side View Mirror 1. Remove door trim panel and water shield as necessary to gain access to side view mirror. 2. Disconnect power side view mirror wire connector, if equipped. 3. Remove nuts holding side view mirror to door frame. 4. Separate mirror from door. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Body Control Module System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 7943 Keyless Entry Module: Diagrams Remote Keyless Entry Module Connectors Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Programming Module Keyless Entry Module: Service and Repair Programming Module PROGRAMMING RKE MODULE The RKE module is capable of retaining up to 4 different VAC(s) when vehicle battery power is interrupted. Replacement or additional key fob transmitter VAC(s) (maximum 4) can be programmed into the Body Control Module (BCM). A functional key fob transmitter is required to program the BCM to accept the new VAC. If a functional key fob transmitter is not available, a scan tool (DRB) can be used to program the BCM. (1) Using a functional key fob, unlock the vehicle and disarm the Vehicle Theft Alarm (2) Insert ignition key into the ignition switch. (3) Switch ignition to RUN position without starting engine. (4) On a functional key fob, actuate and hold the UNLOCK button for a minimum four seconds (maximum ten seconds). (5) While holding UNLOCK button, and before ten seconds passes, actuate and release the PANIC button. A single chime will sound to verify that the RKE module is set to receive the new VAC. (6) Within 30 seconds of the chime, actuate any key on each new key fob transmitter. After 30 seconds or when ignition switch is turned OF{ the RKE module will end the programming mode. A single chime will sound to verify that the RKE module will no longer receive additional VAC(s). (7) When VAC programming is complete, turn OFF ignition switch and verify RKE system operation using each key fob. NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror systems. If a primary key fob is being replaced, the memory seat and mirror module will require programming. Refer to Group 8R, Power Seats for proper (data link) programming procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Programming Module > Page 7946 Keyless Entry Module: Service and Repair Remote Keyless Entry Module Replacement REMOVAL (1) Remove instrument panel top cover. (2) Remove screws holding RKE module to instrument panel. (3) Disconnect wire connector from RKE module. (4) Remove module. INSTALLATION Reverse the preceding operation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Power Door Lock Relay: Locations Micro Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 7950 Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Roof Rack Frame > Component Information > Service and Repair Roof Rack Frame: Service and Repair NOTE: The luggage rack skid strips are attached to the roof panel with adhesive strips using the same methods as stick-on body side moldings. Roof Top Luggage Rack 1. Slide side rail end covers from ends of side rails. 2. Remove screws holding rails to roof panel. 3. Separate luggage rack from vehicle. 4. Reverse the preceding operation for installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest for Seat Back: > 232494 > Mar > 94 > Front Seat Back - Squeaking Noise Seat Back: Customer Interest Front Seat Back - Squeaking Noise NO: 23-24-94 GROUP: Body DATE: Mar. 11, 1994 SUBJECT: Front Seat Back Squeak Noise MODELS: 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Front seat squeaks where the seat back meets the seat cushion. The squeak may be experienced while reclining the seat back or while driving the vehicle. The squeak may be caused by the pivot bolt. DIAGNOSIS: With the seat back in the full upright position, apply fore and aft pressure to the top of the seat back. If a squeaking noise is heard at the seat back pivot area, perform the repair procedure. PARTS REQUIRED: AR 4318084 Mopar Lock Lubricant REPAIR PROCEDURE: This bulletin involves lubricating the front seat back pivot bolt. 1. Remove the seat side shield. 2. Apply Mopar Lock Lubricant (P/N 4318084) to the pivot bolt. Use care to prevent soiling the seat upholstery. 3. Apply fore and aft pressure to the top of the seat back to verify the lubricant has reached the squeaking area. Reapply lubricant as necessary. 4. Reinstall the seat side shield. 5. Repeat steps 1 through 4 for the other side, if necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-20-32-90 0.3 Hrs. FAILURE CODE: CX - Squeaks Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 232494 > Mar > 94 > Front Seat Back - Squeaking Noise Seat Back: All Technical Service Bulletins Front Seat Back - Squeaking Noise NO: 23-24-94 GROUP: Body DATE: Mar. 11, 1994 SUBJECT: Front Seat Back Squeak Noise MODELS: 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Front seat squeaks where the seat back meets the seat cushion. The squeak may be experienced while reclining the seat back or while driving the vehicle. The squeak may be caused by the pivot bolt. DIAGNOSIS: With the seat back in the full upright position, apply fore and aft pressure to the top of the seat back. If a squeaking noise is heard at the seat back pivot area, perform the repair procedure. PARTS REQUIRED: AR 4318084 Mopar Lock Lubricant REPAIR PROCEDURE: This bulletin involves lubricating the front seat back pivot bolt. 1. Remove the seat side shield. 2. Apply Mopar Lock Lubricant (P/N 4318084) to the pivot bolt. Use care to prevent soiling the seat upholstery. 3. Apply fore and aft pressure to the top of the seat back to verify the lubricant has reached the squeaking area. Reapply lubricant as necessary. 4. Reinstall the seat side shield. 5. Repeat steps 1 through 4 for the other side, if necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-20-32-90 0.3 Hrs. FAILURE CODE: CX - Squeaks Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Customer Interest: > 232394 > Mar > 94 > Front Seat Adjuster Latch - Does Not Latch Smoothly Seat Latch: Customer Interest Front Seat Adjuster Latch - Does Not Latch Smoothly NO: 23-23-94 GROUP: Body DATE: Mar. 18, 1994 SUBJECT: Front Seat Manual Adjuster Latching NOTE: THIS BULLETIN SUPERSEDES TSB 23-32-93 DATED MAY 14,1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS REVISION ADDS 1994 MODEL VEHICLES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1991 - **1994** (AS) Caravan/Voyager SYMPTOM/CONDITION: Some vehicles may exhibit a condition where one side of the manual seat adjuster may not latch as smoothly as the other side. DIAGNOSIS: This condition may be noticed after the seat has been adjusted and the adjustment handle is released. If one side of the adjuster latches while the other side requires the occupant of the seat to shift their weight in order for it to latch, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves modifying the inboard seat riser. 1. Remove the four nuts attaching the seat adjusters to the seat riser assemblies. (Refer to Figure 1.) 2. Remove the seat assembly from the risers and set it outside of the vehicle. 3. Elongate the rear hole of inboard riser with a rat-tail file or die grinder .080 in. (2 mm) fore and aft, being careful to not enlarge the hole Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Customer Interest: > 232394 > Mar > 94 > Front Seat Adjuster Latch - Does Not Latch Smoothly > Page 7977 side-to-side. (Refer to Figure 2.) 4. Inspect the adjusters and ensure that both sides are engaged at the same tooth position. Reposition the adjusters as necessary. 5. Reinstall the seat assembly to the risers. Torque the four nuts to 250 in.lbs. 6. Verify the repair by performing the diagnosis procedure again. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 23-13-35-94 Right Side (1994 Only) 0.5 Hrs. 23-13-35-95 Left Side (1991-1994) 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 232394 > Mar > 94 > Front Seat Adjuster Latch - Does Not Latch Smoothly Seat Latch: All Technical Service Bulletins Front Seat Adjuster Latch - Does Not Latch Smoothly NO: 23-23-94 GROUP: Body DATE: Mar. 18, 1994 SUBJECT: Front Seat Manual Adjuster Latching NOTE: THIS BULLETIN SUPERSEDES TSB 23-32-93 DATED MAY 14,1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS REVISION ADDS 1994 MODEL VEHICLES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1991 - **1994** (AS) Caravan/Voyager SYMPTOM/CONDITION: Some vehicles may exhibit a condition where one side of the manual seat adjuster may not latch as smoothly as the other side. DIAGNOSIS: This condition may be noticed after the seat has been adjusted and the adjustment handle is released. If one side of the adjuster latches while the other side requires the occupant of the seat to shift their weight in order for it to latch, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves modifying the inboard seat riser. 1. Remove the four nuts attaching the seat adjusters to the seat riser assemblies. (Refer to Figure 1.) 2. Remove the seat assembly from the risers and set it outside of the vehicle. 3. Elongate the rear hole of inboard riser with a rat-tail file or die grinder .080 in. (2 mm) fore and aft, being careful to not enlarge the hole Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 232394 > Mar > 94 > Front Seat Adjuster Latch - Does Not Latch Smoothly > Page 7983 side-to-side. (Refer to Figure 2.) 4. Inspect the adjusters and ensure that both sides are engaged at the same tooth position. Reposition the adjusters as necessary. 5. Reinstall the seat assembly to the risers. Torque the four nuts to 250 in.lbs. 6. Verify the repair by performing the diagnosis procedure again. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 23-13-35-94 Right Side (1994 Only) 0.5 Hrs. 23-13-35-95 Left Side (1991-1994) 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Latch: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop Shift Solenoid: All Technical Service Bulletins A/T - Ratcheting Sound When Coming To Stop NO: 21-10-96 GROUP: Transmission DATE: Jul. 5, 1996 SUBJECT: Ratcheting Sound During Garage Shifts and When Coming to A Stop MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1996 (FJ) Sebring/Avenger/Talon 1996 (GS) Chrysler Voyager (European Market) 1995 - 1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A "racheting" or clicking sound is heard during garage shifts or when the vehicle is coming to a stop. This sound is normal and is associated with the operation of the transaxle shift solenoid. On some vehicles this sound may be more noticeable than others because of variations in sealing of the solenoid sound shield. THE TRANSAXLE SHIFT SOLENOID SHOULD NOT BE REPLACED FOR THIS CONDITION. DIAGNOSIS: With the vehicle operator present, confirm the sound is associated with the transaxle shift solenoid operation by firmly applying the brakes then, while the engine is running, shift the vehicle into gear. If the racheting sound is confirmed, perform the Repair Procedure. PARTS REQUIRED: AR 82300234 Sealant, Mopar RTV REPAIR PROCEDURE: This bulletin involves sealing ALL air gaps between the solenoid sound shield and the transaxle case. NOTE: THIS REPAIR PROCEDURE WILL NOT ELIMINATE THE RACHETING SOUND BUT WILL REDUCE IT AS MUCH AS POSSIBLE. THE RATCHETING SOUND IS A NORMAL CHARACTERISTIC OF THIS TRANSAXLE AND IN NO WAY EFFECTS THE RELIABILITY OR DURABILITY OF THE TRANSAXLE. 1. Clean the area where the solenoid sound shield meets with the transaxle case with steam or other appropriate cleaner. Raising the vehicle on an appropriate hoist and/or removing the air cleaner may be helpful in gaining access to the area. NOTE: DO NOT use petroleum based cleaners because they may deteriorate the sound shield and/or the electrical connectors/components. 2. Blow the area dry with compressed air. 3. Use Mopar RTV sealant (P/N 82300234) to seal ALL air gaps between the solenoid sound shield and the transaxle case. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Latch: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 7989 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Latch: > 211096 > Jul > 96 > A/T - Ratcheting Sound When Coming To Stop > Page 7995 4. Lower the vehicle and install the air cleaner if applicable. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-90-95-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 237494A > Oct > 94 > Quad Seat Floor Attachment - Rattling Noise Seat Track: Customer Interest Quad Seat Floor Attachment - Rattling Noise NO: 23-74-94 Rev. A GROUP: Body DATE: Oct. 28, 1994 SUBJECT: Rattling Noise from Quad Seat Floor Attachment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-74-94 DATED OCT. 7, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION INVOLVES CORRECTION OF A PART NUMBER AND IS HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) SYMPTOM/CONDITION: Rattling noise from quad seat floor attachment when driving over rough roads. DIAGNOSIS: Grasp the back of each quad seat and shake fore and aft and side to side. If a rattle is heard, perform the repair procedure. PARTS REQUIRED: 4 4705758 Bumper 4 154695 Screw 2 ** 4705760 ** Cap REPAIR PROCEDURE: This bulletin involves installing rubber bumpers on the bottom front of the quad seat risers. 1. Unlatch and remove the quad seats from the vehicle. 2. Locate the hole on the bottom side near the front of the quad seat risers and install a rubber bumper, P/N 4705758, on each riser (Refer to illustration). 3. Thread a screw, P/N 154695, into each bumper and tighten until approximately 3/4 in. of the screw protrudes through the bumper. 4. On the left side quad seat install cap, P/N 4705760, over the protruding portion of the screws. 5. Install the quad seats and securely latch. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 237494A > Oct > 94 > Quad Seat Floor Attachment - Rattling Noise > Page 8004 TIME ALLOWANCE: Labor Operation No: 23-13-37-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 233794 > Apr > 94 > Rear Seat Adjuster - Rattle Seat Track: Customer Interest Rear Seat Adjuster - Rattle NO: 23-37-94 GROUP: Body DATE: Apr. 22, 1994 SUBJECT: Rear Seat Adjuster Rattle MODELS: 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BETWEEN 3/15/94 AND 3/25/94 (MDH 03-15-XX THROUGH 03-25-XX). SYMPTOM/CONDITION: Rattle noise from the area of the rear seat left side riser. DIAGNOSIS: Inspect the left rear seat adjuster for a mis-positioned adjuster link wire to adjuster latch arm condition. If this is determined to be the source of the rattle, perform the repair procedure. PARTS REQUIRED: 1 6503043 Fastener, Push Pin REPAIR PROCEDURE: This bulletin involves installing a push pin fastener to prevent a mis-positioned adjuster link wire to adjuster latch arm condition from reoccurring. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 233794 > Apr > 94 > Rear Seat Adjuster - Rattle > Page 8009 1. While holding the rear seat adjuster handle (from behind the seat) to the released position, insert the push pin fastener (P/N 6503043) into the slot of the left adjuster latch arm as illustrated. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-13-37-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 232394 > Mar > 94 > Front Seat Adjuster Latch - Does Not Latch Smoothly Seat Track: Customer Interest Front Seat Adjuster Latch - Does Not Latch Smoothly NO: 23-23-94 GROUP: Body DATE: Mar. 18, 1994 SUBJECT: Front Seat Manual Adjuster Latching NOTE: THIS BULLETIN SUPERSEDES TSB 23-32-93 DATED MAY 14,1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS REVISION ADDS 1994 MODEL VEHICLES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1991 - **1994** (AS) Caravan/Voyager SYMPTOM/CONDITION: Some vehicles may exhibit a condition where one side of the manual seat adjuster may not latch as smoothly as the other side. DIAGNOSIS: This condition may be noticed after the seat has been adjusted and the adjustment handle is released. If one side of the adjuster latches while the other side requires the occupant of the seat to shift their weight in order for it to latch, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves modifying the inboard seat riser. 1. Remove the four nuts attaching the seat adjusters to the seat riser assemblies. (Refer to Figure 1.) 2. Remove the seat assembly from the risers and set it outside of the vehicle. 3. Elongate the rear hole of inboard riser with a rat-tail file or die grinder .080 in. (2 mm) fore and aft, being careful to not enlarge the hole Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 232394 > Mar > 94 > Front Seat Adjuster Latch - Does Not Latch Smoothly > Page 8014 side-to-side. (Refer to Figure 2.) 4. Inspect the adjusters and ensure that both sides are engaged at the same tooth position. Reposition the adjusters as necessary. 5. Reinstall the seat assembly to the risers. Torque the four nuts to 250 in.lbs. 6. Verify the repair by performing the diagnosis procedure again. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 23-13-35-94 Right Side (1994 Only) 0.5 Hrs. 23-13-35-95 Left Side (1991-1994) 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 231194 > Feb > 94 > Rear Seat - High Sliding Effort Seat Track: Customer Interest Rear Seat - High Sliding Effort NO: 23-11-94 GROUP: Body DATE: Feb. 4, 1994 SUBJECT: Rear Seat Sliding Effort MODELS: 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: Complaints of high effort required to slide the rear bench seat to achieve the desired fore and aft adjustment may be encountered. Prior to any parts replacement, slide the rear seat fore and aft through the full range of travel approximately 15 times. This will burnish the adjuster tracks and reduce the effort required to slide the bench seat fore and aft. If the effort required is still unacceptable, lubricate the adjuster slides with Mopar Silicone Spray Lube, P/N 4318070. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 237494A > Oct > 94 > Quad Seat Floor Attachment - Rattling Noise Seat Track: All Technical Service Bulletins Quad Seat Floor Attachment - Rattling Noise NO: 23-74-94 Rev. A GROUP: Body DATE: Oct. 28, 1994 SUBJECT: Rattling Noise from Quad Seat Floor Attachment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-74-94 DATED OCT. 7, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION INVOLVES CORRECTION OF A PART NUMBER AND IS HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) SYMPTOM/CONDITION: Rattling noise from quad seat floor attachment when driving over rough roads. DIAGNOSIS: Grasp the back of each quad seat and shake fore and aft and side to side. If a rattle is heard, perform the repair procedure. PARTS REQUIRED: 4 4705758 Bumper 4 154695 Screw 2 ** 4705760 ** Cap REPAIR PROCEDURE: This bulletin involves installing rubber bumpers on the bottom front of the quad seat risers. 1. Unlatch and remove the quad seats from the vehicle. 2. Locate the hole on the bottom side near the front of the quad seat risers and install a rubber bumper, P/N 4705758, on each riser (Refer to illustration). 3. Thread a screw, P/N 154695, into each bumper and tighten until approximately 3/4 in. of the screw protrudes through the bumper. 4. On the left side quad seat install cap, P/N 4705760, over the protruding portion of the screws. 5. Install the quad seats and securely latch. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 237494A > Oct > 94 > Quad Seat Floor Attachment - Rattling Noise > Page 8024 TIME ALLOWANCE: Labor Operation No: 23-13-37-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 233794 > Apr > 94 > Rear Seat Adjuster - Rattle Seat Track: All Technical Service Bulletins Rear Seat Adjuster - Rattle NO: 23-37-94 GROUP: Body DATE: Apr. 22, 1994 SUBJECT: Rear Seat Adjuster Rattle MODELS: 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BETWEEN 3/15/94 AND 3/25/94 (MDH 03-15-XX THROUGH 03-25-XX). SYMPTOM/CONDITION: Rattle noise from the area of the rear seat left side riser. DIAGNOSIS: Inspect the left rear seat adjuster for a mis-positioned adjuster link wire to adjuster latch arm condition. If this is determined to be the source of the rattle, perform the repair procedure. PARTS REQUIRED: 1 6503043 Fastener, Push Pin REPAIR PROCEDURE: This bulletin involves installing a push pin fastener to prevent a mis-positioned adjuster link wire to adjuster latch arm condition from reoccurring. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 233794 > Apr > 94 > Rear Seat Adjuster - Rattle > Page 8029 1. While holding the rear seat adjuster handle (from behind the seat) to the released position, insert the push pin fastener (P/N 6503043) into the slot of the left adjuster latch arm as illustrated. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-13-37-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 232394 > Mar > 94 > Front Seat Adjuster Latch - Does Not Latch Smoothly Seat Track: All Technical Service Bulletins Front Seat Adjuster Latch - Does Not Latch Smoothly NO: 23-23-94 GROUP: Body DATE: Mar. 18, 1994 SUBJECT: Front Seat Manual Adjuster Latching NOTE: THIS BULLETIN SUPERSEDES TSB 23-32-93 DATED MAY 14,1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS REVISION ADDS 1994 MODEL VEHICLES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1991 - **1994** (AS) Caravan/Voyager SYMPTOM/CONDITION: Some vehicles may exhibit a condition where one side of the manual seat adjuster may not latch as smoothly as the other side. DIAGNOSIS: This condition may be noticed after the seat has been adjusted and the adjustment handle is released. If one side of the adjuster latches while the other side requires the occupant of the seat to shift their weight in order for it to latch, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves modifying the inboard seat riser. 1. Remove the four nuts attaching the seat adjusters to the seat riser assemblies. (Refer to Figure 1.) 2. Remove the seat assembly from the risers and set it outside of the vehicle. 3. Elongate the rear hole of inboard riser with a rat-tail file or die grinder .080 in. (2 mm) fore and aft, being careful to not enlarge the hole Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 232394 > Mar > 94 > Front Seat Adjuster Latch - Does Not Latch Smoothly > Page 8034 side-to-side. (Refer to Figure 2.) 4. Inspect the adjusters and ensure that both sides are engaged at the same tooth position. Reposition the adjusters as necessary. 5. Reinstall the seat assembly to the risers. Torque the four nuts to 250 in.lbs. 6. Verify the repair by performing the diagnosis procedure again. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 23-13-35-94 Right Side (1994 Only) 0.5 Hrs. 23-13-35-95 Left Side (1991-1994) 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 231194 > Feb > 94 > Rear Seat - High Sliding Effort Seat Track: All Technical Service Bulletins Rear Seat - High Sliding Effort NO: 23-11-94 GROUP: Body DATE: Feb. 4, 1994 SUBJECT: Rear Seat Sliding Effort MODELS: 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: Complaints of high effort required to slide the rear bench seat to achieve the desired fore and aft adjustment may be encountered. Prior to any parts replacement, slide the rear seat fore and aft through the full range of travel approximately 15 times. This will burnish the adjuster tracks and reduce the effort required to slide the bench seat fore and aft. If the effort required is still unacceptable, lubricate the adjuster slides with Mopar Silicone Spray Lube, P/N 4318070. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest: > 021994 > Nov > 94 > Front Suspension - Rapping Noise On Bumps Strut / Shock Tower: Customer Interest Front Suspension - Rapping Noise On Bumps NO: 02-19-94 GROUP: Front Suspension DATE: Nov. 25, 1994 SUBJECT: Front Suspension Rapping Noise When Traveling Over Bumps THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-08-93 DATED OCT. 29, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 - **1995** (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A metal to metal rapping noise can be heard coming from the front suspension when traveling over bumps. DIAGNOSIS: With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If contact is evident, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves providing additional clearance between the front coil spring(s) and strut tower(s). 1. With the vehicle on a hoist, remove the front strut assembly(s). 2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against the sheetmetal of the strut tower, their contours match. 3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 in. (6 mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the reference. 4. Repair the paint of the reworked area both in the wheel well and the engine compartment as necessary. Use the paint manufacturer anti-corrosion recommendations. 5. Reinstall the strut assembly(s). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest: > 021994 > Nov > 94 > Front Suspension - Rapping Noise On Bumps > Page 8051 6. Use the proper procedure to set the front suspension camber to +0.3 degrees and toe adjustment 0.1 degree toe in. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 02-27-01-94 (One Side) 1.4 Hrs. 02-27-01-95 (Both Sides) 1.9 Hrs. FAILURE CODE: XX - Service Adjustments Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest: > 020893 > Oct > 93 > Front Coil Spring - Metallic Rapping Noise Strut / Shock Tower: Customer Interest Front Coil Spring - Metallic Rapping Noise NO.: 02-08-93 GROUP: Front Suspension DATE: Oct. 29, 1993 SUBJECT: Noise Due To Coil Spring To Strut Tower Contact MODELS: 1994 (AS) Grand Caravan/Caravan CV/Grand Voyager/Town & Country NOTE: THIS BULLETIN APPLIES TO LONG WHEEL BASE VEHICLES BUILT PRIOR TO 8/20/93 (MDH 0820xx). SYMPTOM/CONDITION: A metal to metal rapping noise can be heard coming from the front suspension when traveling over bumps. This noise is caused by the front coil spring(s) coming into contact with the strut tower(s). DIAGNOSIS: With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If contact is evident, perform the repair procedure. REPAIR PROCEDURE: This repair involves providing additional clearance between the front coil spring(s) and strut tower(s). 1. With the vehicle on a hoist, remove the front strut assembly(s) using the procedure outlined in the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105) beginning on page 2-8. 2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against the sheetmetal of the strut tower, their contours match. 3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 In. (6 mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the reference. 4. Repair the paint of the reworked area both in the wheel well and the engine compartment as necessary. Use the paint manufacturer anti-corrosion Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest: > 020893 > Oct > 93 > Front Coil Spring - Metallic Rapping Noise > Page 8056 recommendations. 5. Reinstall the strut assembly(s). 6. Use the procedure outlined in the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105) beginning on page 2-6 to set the front suspension camber to +0.3 degrees and toe adjustment 0.1 degree tow in. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 02-27-01-94 One Side 1.4 Hrs. 02-27-01-95 Both Sides 1.9 Hrs. FAILURE CODE: XX - Service Adjustments Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 021994 > Nov > 94 > Front Suspension - Rapping Noise On Bumps Strut / Shock Tower: All Technical Service Bulletins Front Suspension - Rapping Noise On Bumps NO: 02-19-94 GROUP: Front Suspension DATE: Nov. 25, 1994 SUBJECT: Front Suspension Rapping Noise When Traveling Over Bumps THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-08-93 DATED OCT. 29, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1994 - **1995** (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A metal to metal rapping noise can be heard coming from the front suspension when traveling over bumps. DIAGNOSIS: With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If contact is evident, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves providing additional clearance between the front coil spring(s) and strut tower(s). 1. With the vehicle on a hoist, remove the front strut assembly(s). 2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against the sheetmetal of the strut tower, their contours match. 3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 in. (6 mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the reference. 4. Repair the paint of the reworked area both in the wheel well and the engine compartment as necessary. Use the paint manufacturer anti-corrosion recommendations. 5. Reinstall the strut assembly(s). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 021994 > Nov > 94 > Front Suspension - Rapping Noise On Bumps > Page 8062 6. Use the proper procedure to set the front suspension camber to +0.3 degrees and toe adjustment 0.1 degree toe in. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 02-27-01-94 (One Side) 1.4 Hrs. 02-27-01-95 (Both Sides) 1.9 Hrs. FAILURE CODE: XX - Service Adjustments Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 240294 > Jan > 94 > A/C Hose - Squeaking Noise Strut / Shock Tower: All Technical Service Bulletins A/C Hose - Squeaking Noise NO: 24-02-94 GROUP: Heat & A/C DATE: Jan. 14, 1994 SUBJECT: Squeak in Right Shock Tower Area MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: If a squeaking noise seems to be coming from the right shock tower, a possible cause is the right shock tower A/C hose support bracket. This should be checked prior to looking elsewhere on or in the shock tower. If the insulation foam between the bracket and hoses is mis-positioned or worn through, a squeak may occur under driving conditions. Inspect the hose and bracket area and relocate or replace the foam or bend the bracket to eliminate any metal-to-metal contact. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 020893 > Oct > 93 > Front Coil Spring - Metallic Rapping Noise Strut / Shock Tower: All Technical Service Bulletins Front Coil Spring - Metallic Rapping Noise NO.: 02-08-93 GROUP: Front Suspension DATE: Oct. 29, 1993 SUBJECT: Noise Due To Coil Spring To Strut Tower Contact MODELS: 1994 (AS) Grand Caravan/Caravan CV/Grand Voyager/Town & Country NOTE: THIS BULLETIN APPLIES TO LONG WHEEL BASE VEHICLES BUILT PRIOR TO 8/20/93 (MDH 0820xx). SYMPTOM/CONDITION: A metal to metal rapping noise can be heard coming from the front suspension when traveling over bumps. This noise is caused by the front coil spring(s) coming into contact with the strut tower(s). DIAGNOSIS: With the vehicle raised on a hoist, inspect the strut tower(s) at the inboard, aft, lower area for witness marks indicating contact with the coil spring(s) is occurring. Refer to the illustration. If contact is evident, perform the repair procedure. REPAIR PROCEDURE: This repair involves providing additional clearance between the front coil spring(s) and strut tower(s). 1. With the vehicle on a hoist, remove the front strut assembly(s) using the procedure outlined in the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105) beginning on page 2-8. 2. Make a cardboard template(s) of the strut tower(s) surface that overlaps the area where spring contact has occurred. Do this by cutting the cardboard so when its edge is placed vertically against the sheetmetal of the strut tower, their contours match. 3. Work the sheetmetal of the strut tower(s) with an appropriate tool so a clearance of 1/4 In. (6 mm) is obtained at the point where the witness marks of contact exist. Use the template(s) as the reference. 4. Repair the paint of the reworked area both in the wheel well and the engine compartment as necessary. Use the paint manufacturer anti-corrosion Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 020893 > Oct > 93 > Front Coil Spring - Metallic Rapping Noise > Page 8071 recommendations. 5. Reinstall the strut assembly(s). 6. Use the procedure outlined in the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105) beginning on page 2-6 to set the front suspension camber to +0.3 degrees and toe adjustment 0.1 degree tow in. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 02-27-01-94 One Side 1.4 Hrs. 02-27-01-95 Both Sides 1.9 Hrs. FAILURE CODE: XX - Service Adjustments Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Other Service Bulletins for Strut / Shock Tower: > 240294 > Jan > 94 > A/C Hose - Squeaking Noise Strut / Shock Tower: All Technical Service Bulletins A/C Hose - Squeaking Noise NO: 24-02-94 GROUP: Heat & A/C DATE: Jan. 14, 1994 SUBJECT: Squeak in Right Shock Tower Area MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: If a squeaking noise seems to be coming from the right shock tower, a possible cause is the right shock tower A/C hose support bracket. This should be checked prior to looking elsewhere on or in the shock tower. If the insulation foam between the bracket and hoses is mis-positioned or worn through, a squeak may occur under driving conditions. Inspect the hose and bracket area and relocate or replace the foam or bend the bracket to eliminate any metal-to-metal contact. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Windshield/Cowl - Squeak Elimination Cowl: Technical Service Bulletins Windshield/Cowl - Squeak Elimination NO: 23-27-94 GROUP: Body DATE: Mar. 18, 1994 SUBJECT: Squeak Noise At The Base Of The Windshield MODELS: 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: Water soluble support spacers are used in the windshield installation process at the assembly plant to properly position the windshield. During the transit and vehicle predelivery processes, if enough water does not come in contact with the windshield support spacers, they may not dissolve as intended and may cause a squeaking noise. Typically, enough water contacts the windshield support spacers during a car wash. Prior to delivering the new vehicle to the customer, look for the support spacers at both sides of the base of the windshield (refer to the illustration). If the support spacers are still in place, raise the cowl and pry them out or slowly pour two gallons of hot water directly on them until they dissolve. This will prevent the customer from experiencing a squeak condition on the new vehicle. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Frame Rear Molding Front Door Weatherstrip: Service and Repair Front Door Frame Rear Molding Belt Moulding And Weatherstrip 1. Remove belt molding and weatherstrip as necessary to clear door frame molding removal path. 2. Remove glass run weatherstrip to gain access to molding clips. 3. Disengage clips holding door frame molding to door frame 4. Separate molding from door. 5. Reverse the preceding operation for installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Door Frame Rear Molding > Page 8087 Front Door Weatherstrip: Service and Repair Front Door Belt Molding and Weatherstrip VAN ONLY Belt Moulding And Weatherstrip 1. Remove door glass. 2. Remove side view mirror. 3. Remove screws holding belt molding and weatherstrip to door panel. 4. Separate belt molding and weatherstrip from door. 5. Reverse the preceding operation for installation. WAGON ONLY Belt Moulding And Weatherstrip 1. Remove door glass. 2. Remove side view mirror. 3. Remove door glass run weatherstrip. 4. Disengage clips holding door frame molding to door frame. 5. Remove screws holding belt molding and weatherstrip to door panel. 6. Separate belt molding and weatherstrip from door. 7. Reverse the preceding operation for installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair Glass Channel And Run Weatherstrip 1. Lower door glass to down position. 2. Remove side view mirror as necessary to gain clearance for weatherstrip removal. 3. Pull glass run weatherstrip from door frame channel. 4. Reverse the preceding operation for installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection 1. Remove stop lamp switch, then inspect for continuity between terminal No. 5 and No. 6 with plunger released. Continuity Should exist. 2. Inspect for continuity between terminal No. 1 and No. 2 with plunger depressed. Continuity Should exist. 3. Inspect for continuity between terminal No. 3 and No. 4 with plunger depressed. Continuity Should exist. 4. If continuity is not as specified, then stop lamp switch is out of adjustment or defective. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Description and Operation Speed Control Servo: Description and Operation PURPOSE Actuated by the PCM to obtain and maintain a selected road speed. Houses the throttle actuator, speed control vacuum solenoid, and speed control vent solenoid. OPERATION Power to the solenoids is supplied by the speed control relay. The Powertrain Control Module (PCM) actuates the vacuum and vent solenoids, by switching the ground path on and off. - When the PCM grounds vacuum solenoid, the speed control system opens the throttle to obtain a selected road speed. - When the PCM grounds vent solenoid, the speed control system closes the throttle to reduce road speed. - The PCM balances the two solenoids to maintain a selected road speed. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Description and Operation > Page 8098 Speed Control Servo: Testing and Inspection 1. Turn ignition switch and speed control switch to the ON position. 2. Set voltmeter to read battery voltage. Connect negative lead to chassis ground. Fig. 72 Servo Harness Connector 3. Disconnect 4-way connector at servo. Pin 2 should read approximately battery voltage. If not, check for loose connections or repair main harness as necessary. 4. If voltage reading is satisfactory, check fuse. 5. Disconnect six-way connector from stop lamp switch, then test pin 3 for battery voltage. If voltage is satisfactory, perform "Stop Lamp Switch Test." 6. If Stop Lamp Switch test is satisfactory, repair wire between servo and stop lamp switch. 7. If voltage is not present at pin 3, disconnect four-way speed control connector, then test pin 1 for battery voltage. 8. If voltage is present, perform "Speed Control Switch Test." 9. If no voltage is present at pin 1, test pin 2 of the six-way stop lamp switch connector for battery voltage. 10. If voltage is not present, repair wiring as necessary. 11. If speed control switch is satisfactory, check clockspring for continuity. 12. If clockspring continuity is satisfactory, repair wire between stop lamp switch and clockspring. 13. If voltage is not present at pin 1 of the four-way speed control switch connector, check for battery voltage between ignition and fuse. 14. Check continuity between fuse and clockspring. 15. Connect jumper wire between pin 2 of the four-way connector and pin 2 of the speed control servo. Pin 1, 3 & 4 of the servo should show battery voltage. 16. If these terminals do not measure as specified, replace servo. 17. Using an ohmmeter, connect negative lead to chassis ground, then positive lead to pin 1 of the four-way connector of the main harness. 18. Ohmmeter should show continuity. If not, repair ground circuit as necessary. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Description and Operation > Page 8099 Speed Control Servo: Service and Repair 1. Remove two nuts attaching speed control cable and mounting bracket to servo. 2. Remove two screws attaching servo mounting bracket to U-nuts on battery tray. 3. Remove servo mounting bracket. 4. Disconnect electrical connector and vacuum hose. 5. Pull cable away from servo to expose retaining clip, then remove clip. 6. Install with throttle in full open position. Align hole in throttle cable sleeve with hole in servo pin, then install retaining pin. 7. Connect vacuum hose and electrical connector to servo. 8. Position mounting bracket, then install both screws, attaching bracket to battery tray. Torque screws to 8.75 ft. lbs. 9. Insert servo studs through holes in throttle cable and mounting bracket. Install nuts, then torque to 6.6 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair Cruise Control Servo Cable: Service and Repair 1. Remove air cleaner assembly. 2. Disconnect cable from throttle body by removing retaining clip. 3. Disconnect cable from servo, then remove cable assembly. 4. Locate cable through servo mounting bracket. 5. Connect cable sleeve to servo stud, align holes, then install clip. 6. Insert servo studs through holes in cable and holes in bracket, then install nut-washers. 7. Route cable from servo, through cable support bracket and clip, then install cable end on stud of throttle body. 8. Replace air cleaner. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Customer Interest: > 081694 > Apr > 94 > Speed Control Switch - Loose/Rattles Cruise Control Switch: Customer Interest Speed Control Switch - Loose/Rattles NO: 08-16-94 GROUP: Electrical DATE: Apr. 1, 1994 SUBJECT: Speed Control Switch Loose or Rattles MODELS: 1994 (AA) Acclaim/LeBaron Sedan/Spirit (AJ) LeBaron Convertible (AP) Shadow/Sundance (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE STANDARD (NON-LEATHER WRAPPED) STEERING WHEEL, EXCLUDING LONG WHEEL BASE AS-BODY, BUILT PRIOR TO 3/7/94, (MDH 03-07-XX). SYMPTOM/CONDITION: Speed control switch becomes loose or rattles in steering wheel. The most likely cause is cracking of the speed control switch mounting bosses due to lubricant under the paint and on the metal mounting surface of the steering wheel. Additionally, the switch mounting screw holes may be located too far outboard. PARTS REQUIRED: 1 4565265 Speed Control Switch 2 6032986 Screws AR NPN Naphtha Cleaning Solvent (Obtain Locally) REPAIR PROCEDURE: This bulletin involves enlarging the speed control switch mounting holes, cleaning the steering wheel mounting surface, top and bottom, and installing a new speed control switch and mounting screws. 1. Remove the speed control switch from the steering wheel and discard the two mounting screws. NOTE: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE REMOVING THE AIRBAG. FOLLOW ALL WARNINGS IN THE APPROPRIATE SERVICE MANUAL REGARDING AIRBAGS. 2. Remove the steering wheel by removing the airbag module, vibration dampener (if equipped), and speed control wiring as outlined in the appropriate Service Manual. 3. With the steering wheel removed, remove the back cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Customer Interest: > 081694 > Apr > 94 > Speed Control Switch - Loose/Rattles > Page 8111 4. Secure the steering wheel in a suitable fixture. Drill out both speed control mounting holes using a 1/4" (6 mm) drill (See Illustration). 5. Using 80 to 180 grit sandpaper, clean the paint off both the top and bottom sides of metal mounting surface. Using a round file or knife, clean out both guide pin holes where the speed control switch mounts (See Illustration). 6. Clean loose debris from the sanded area. Using Naphtha cleaning solvent on a clean rag, thoroughly wipe the sanded area on both sides of the steering wheel. Make sure screw and guide pin holes are also cleaned out with solvent. Allow 2-3 minutes for cleaner to evaporate. NOTE: USE ONLY NAPHTHA CLEANING SOLVENT. ANY OTHER SOLVENT WILL NOT BE EFFECTIVE FOR THIS PROCEDURE. WHEN USING NAPHTHA, FOLLOW ALL MANUFACTURERS WARNINGS AND RECOMMENDATIONS AND AVOID CONTACT WITH PLASTIC SURFACES. 7. Reinstall the steering wheel back cover, steering wheel and all other parts removed in Step 2. 8. Install new speed control switch, P/N 4565265, using two new screws, P/N 6032986. NOTE: THE OLD SPEED CONTROL SWITCH MOUNTING SCREWS MUST NOT BE REUSED, AS THEY MAY BE CONTAMINATED WITH LUBRICANT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-85-30-93 0.5 Hrs. FAILURE CODE: BF - Broken Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 081694 > Apr > 94 > Speed Control Switch - Loose/Rattles Cruise Control Switch: All Technical Service Bulletins Speed Control Switch - Loose/Rattles NO: 08-16-94 GROUP: Electrical DATE: Apr. 1, 1994 SUBJECT: Speed Control Switch Loose or Rattles MODELS: 1994 (AA) Acclaim/LeBaron Sedan/Spirit (AJ) LeBaron Convertible (AP) Shadow/Sundance (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE STANDARD (NON-LEATHER WRAPPED) STEERING WHEEL, EXCLUDING LONG WHEEL BASE AS-BODY, BUILT PRIOR TO 3/7/94, (MDH 03-07-XX). SYMPTOM/CONDITION: Speed control switch becomes loose or rattles in steering wheel. The most likely cause is cracking of the speed control switch mounting bosses due to lubricant under the paint and on the metal mounting surface of the steering wheel. Additionally, the switch mounting screw holes may be located too far outboard. PARTS REQUIRED: 1 4565265 Speed Control Switch 2 6032986 Screws AR NPN Naphtha Cleaning Solvent (Obtain Locally) REPAIR PROCEDURE: This bulletin involves enlarging the speed control switch mounting holes, cleaning the steering wheel mounting surface, top and bottom, and installing a new speed control switch and mounting screws. 1. Remove the speed control switch from the steering wheel and discard the two mounting screws. NOTE: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE REMOVING THE AIRBAG. FOLLOW ALL WARNINGS IN THE APPROPRIATE SERVICE MANUAL REGARDING AIRBAGS. 2. Remove the steering wheel by removing the airbag module, vibration dampener (if equipped), and speed control wiring as outlined in the appropriate Service Manual. 3. With the steering wheel removed, remove the back cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 081694 > Apr > 94 > Speed Control Switch - Loose/Rattles > Page 8117 4. Secure the steering wheel in a suitable fixture. Drill out both speed control mounting holes using a 1/4" (6 mm) drill (See Illustration). 5. Using 80 to 180 grit sandpaper, clean the paint off both the top and bottom sides of metal mounting surface. Using a round file or knife, clean out both guide pin holes where the speed control switch mounts (See Illustration). 6. Clean loose debris from the sanded area. Using Naphtha cleaning solvent on a clean rag, thoroughly wipe the sanded area on both sides of the steering wheel. Make sure screw and guide pin holes are also cleaned out with solvent. Allow 2-3 minutes for cleaner to evaporate. NOTE: USE ONLY NAPHTHA CLEANING SOLVENT. ANY OTHER SOLVENT WILL NOT BE EFFECTIVE FOR THIS PROCEDURE. WHEN USING NAPHTHA, FOLLOW ALL MANUFACTURERS WARNINGS AND RECOMMENDATIONS AND AVOID CONTACT WITH PLASTIC SURFACES. 7. Reinstall the steering wheel back cover, steering wheel and all other parts removed in Step 2. 8. Install new speed control switch, P/N 4565265, using two new screws, P/N 6032986. NOTE: THE OLD SPEED CONTROL SWITCH MOUNTING SCREWS MUST NOT BE REUSED, AS THEY MAY BE CONTAMINATED WITH LUBRICANT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-85-30-93 0.5 Hrs. FAILURE CODE: BF - Broken Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 230394 > Jan > 94 > Middle Bench Seat Outer Seatbelt - High Extension Effort Seat Belt: All Technical Service Bulletins Middle Bench Seat Outer Seatbelt - High Extension Effort NO: 23-03-94 GROUP: Body DATE: Jan. 21, 1994 SUBJECT: Middle Bench Seat Left Seat Belt MODELS: 1994 (AS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO SHORT WHEEL BASE (SWB) VEHICLES. SYMPTOM/CONDITION: High effort is required to extend the middle bench seat left seat belt or the seat belt will not return to the stowed position. DIAGNOSIS: Extend the seat belt. If high effort is required or the seat belt will not return, perform the repair procedure. REPAIR PROCEDURE: This bulletin involves trimming the silencer pad on the back side of the left upper quarter trim panel. 1. Using the procedure outlined (steps 1-4) on Page 23-39 of the 1994 Town & Country/Caravan/Voyager Service Manual (Publication No. 81-370-4105) remove the left quarter trim insert. 2. Remove the silencer material from the back side of the upper quarter trim panel from the area shown in the illustration. 3. Reverse the procedure in step 1 to reinstall the interior trim. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 23-20-56-91 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 8128 Cruise Control Switch: Testing and Inspection 1. Disconnect the blade type four wire electrical connector from base of steering column. 2. Using a continuity tester, or an ohmmeter, check for continuity at connector wires. Do not use a test light. Fig. 108 Speed Control Continuity Chart Fig. 8 Speed Control Connector Terminal Identification 3. Results should be obtained according to the chart. If these results are not obtained, replace switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 8129 Cruise Control Switch: Service and Repair 1. Disconnect battery ground cable. 2. Turn ignition switch to the Off position. 3. Remove two screws from back of steering wheel. 4. Rock switch away from air bag or horn pad while lifting switch from steering wheel. 5. Disconnect four-way electrical connector. 6. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Solenoid > Component Information > Description and Operation Cruise Control Vacuum Solenoid: Description and Operation PURPOSE Maintain set speed. Vent vacuum and disable system if there is a brake application or the switch is turned off. OPERATION PCM actuates solenoids by applying or removing circuit grounds. PCM uses various input signals to determine solenoid activation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Vent Solenoid > Component Information > Description and Operation Cruise Control Vacuum Vent Solenoid: Description and Operation PURPOSE Maintain set speed. Vent vacuum and disable system if there is a brake application or the switch is turned off. OPERATION PCM actuates solenoids by applying or removing circuit grounds. PCM uses various input signals to determine solenoid activation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection 1. Remove stop lamp switch, then inspect for continuity between terminal No. 5 and No. 6 with plunger released. Continuity Should exist. 2. Inspect for continuity between terminal No. 1 and No. 2 with plunger depressed. Continuity Should exist. 3. Inspect for continuity between terminal No. 3 and No. 4 with plunger depressed. Continuity Should exist. 4. If continuity is not as specified, then stop lamp switch is out of adjustment or defective. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Customer Interest: > 081694 > Apr > 94 > Speed Control Switch - Loose/Rattles Cruise Control Switch: Customer Interest Speed Control Switch - Loose/Rattles NO: 08-16-94 GROUP: Electrical DATE: Apr. 1, 1994 SUBJECT: Speed Control Switch Loose or Rattles MODELS: 1994 (AA) Acclaim/LeBaron Sedan/Spirit (AJ) LeBaron Convertible (AP) Shadow/Sundance (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE STANDARD (NON-LEATHER WRAPPED) STEERING WHEEL, EXCLUDING LONG WHEEL BASE AS-BODY, BUILT PRIOR TO 3/7/94, (MDH 03-07-XX). SYMPTOM/CONDITION: Speed control switch becomes loose or rattles in steering wheel. The most likely cause is cracking of the speed control switch mounting bosses due to lubricant under the paint and on the metal mounting surface of the steering wheel. Additionally, the switch mounting screw holes may be located too far outboard. PARTS REQUIRED: 1 4565265 Speed Control Switch 2 6032986 Screws AR NPN Naphtha Cleaning Solvent (Obtain Locally) REPAIR PROCEDURE: This bulletin involves enlarging the speed control switch mounting holes, cleaning the steering wheel mounting surface, top and bottom, and installing a new speed control switch and mounting screws. 1. Remove the speed control switch from the steering wheel and discard the two mounting screws. NOTE: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE REMOVING THE AIRBAG. FOLLOW ALL WARNINGS IN THE APPROPRIATE SERVICE MANUAL REGARDING AIRBAGS. 2. Remove the steering wheel by removing the airbag module, vibration dampener (if equipped), and speed control wiring as outlined in the appropriate Service Manual. 3. With the steering wheel removed, remove the back cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Customer Interest: > 081694 > Apr > 94 > Speed Control Switch - Loose/Rattles > Page 8148 4. Secure the steering wheel in a suitable fixture. Drill out both speed control mounting holes using a 1/4" (6 mm) drill (See Illustration). 5. Using 80 to 180 grit sandpaper, clean the paint off both the top and bottom sides of metal mounting surface. Using a round file or knife, clean out both guide pin holes where the speed control switch mounts (See Illustration). 6. Clean loose debris from the sanded area. Using Naphtha cleaning solvent on a clean rag, thoroughly wipe the sanded area on both sides of the steering wheel. Make sure screw and guide pin holes are also cleaned out with solvent. Allow 2-3 minutes for cleaner to evaporate. NOTE: USE ONLY NAPHTHA CLEANING SOLVENT. ANY OTHER SOLVENT WILL NOT BE EFFECTIVE FOR THIS PROCEDURE. WHEN USING NAPHTHA, FOLLOW ALL MANUFACTURERS WARNINGS AND RECOMMENDATIONS AND AVOID CONTACT WITH PLASTIC SURFACES. 7. Reinstall the steering wheel back cover, steering wheel and all other parts removed in Step 2. 8. Install new speed control switch, P/N 4565265, using two new screws, P/N 6032986. NOTE: THE OLD SPEED CONTROL SWITCH MOUNTING SCREWS MUST NOT BE REUSED, AS THEY MAY BE CONTAMINATED WITH LUBRICANT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-85-30-93 0.5 Hrs. FAILURE CODE: BF - Broken Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 081694 > Apr > 94 > Speed Control Switch Loose/Rattles Cruise Control Switch: All Technical Service Bulletins Speed Control Switch - Loose/Rattles NO: 08-16-94 GROUP: Electrical DATE: Apr. 1, 1994 SUBJECT: Speed Control Switch Loose or Rattles MODELS: 1994 (AA) Acclaim/LeBaron Sedan/Spirit (AJ) LeBaron Convertible (AP) Shadow/Sundance (AS) Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE STANDARD (NON-LEATHER WRAPPED) STEERING WHEEL, EXCLUDING LONG WHEEL BASE AS-BODY, BUILT PRIOR TO 3/7/94, (MDH 03-07-XX). SYMPTOM/CONDITION: Speed control switch becomes loose or rattles in steering wheel. The most likely cause is cracking of the speed control switch mounting bosses due to lubricant under the paint and on the metal mounting surface of the steering wheel. Additionally, the switch mounting screw holes may be located too far outboard. PARTS REQUIRED: 1 4565265 Speed Control Switch 2 6032986 Screws AR NPN Naphtha Cleaning Solvent (Obtain Locally) REPAIR PROCEDURE: This bulletin involves enlarging the speed control switch mounting holes, cleaning the steering wheel mounting surface, top and bottom, and installing a new speed control switch and mounting screws. 1. Remove the speed control switch from the steering wheel and discard the two mounting screws. NOTE: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE BEFORE REMOVING THE AIRBAG. FOLLOW ALL WARNINGS IN THE APPROPRIATE SERVICE MANUAL REGARDING AIRBAGS. 2. Remove the steering wheel by removing the airbag module, vibration dampener (if equipped), and speed control wiring as outlined in the appropriate Service Manual. 3. With the steering wheel removed, remove the back cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 081694 > Apr > 94 > Speed Control Switch Loose/Rattles > Page 8154 4. Secure the steering wheel in a suitable fixture. Drill out both speed control mounting holes using a 1/4" (6 mm) drill (See Illustration). 5. Using 80 to 180 grit sandpaper, clean the paint off both the top and bottom sides of metal mounting surface. Using a round file or knife, clean out both guide pin holes where the speed control switch mounts (See Illustration). 6. Clean loose debris from the sanded area. Using Naphtha cleaning solvent on a clean rag, thoroughly wipe the sanded area on both sides of the steering wheel. Make sure screw and guide pin holes are also cleaned out with solvent. Allow 2-3 minutes for cleaner to evaporate. NOTE: USE ONLY NAPHTHA CLEANING SOLVENT. ANY OTHER SOLVENT WILL NOT BE EFFECTIVE FOR THIS PROCEDURE. WHEN USING NAPHTHA, FOLLOW ALL MANUFACTURERS WARNINGS AND RECOMMENDATIONS AND AVOID CONTACT WITH PLASTIC SURFACES. 7. Reinstall the steering wheel back cover, steering wheel and all other parts removed in Step 2. 8. Install new speed control switch, P/N 4565265, using two new screws, P/N 6032986. NOTE: THE OLD SPEED CONTROL SWITCH MOUNTING SCREWS MUST NOT BE REUSED, AS THEY MAY BE CONTAMINATED WITH LUBRICANT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-85-30-93 0.5 Hrs. FAILURE CODE: BF - Broken Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 220794 > Oct > 94 > Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left Cross-Member: All Technical Service Bulletins Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left NO: 22-07-94 GROUP: Tires and Wheels DATE: Oct. 21, 1994 SUBJECT: Tire Leads/Drifts Left THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-04-93 DATED JUN. 11, 1993 WHICH SHOULD BE NOTED IN YOUR FILES AND THE 1993 TECHNICAL SERVICE BULLETINS MANUAL (PUBLICATION NO. 81-699-94000). THIS REVISION INCLUDES ADDING 1994 AND 1995 MODEL VEHICLES, ADDS STEP 8 AND CHANGES THE FAILURE CODE. ALL REVISIONS ARE HIGHLIGHTED AND WITH **ASTERISKS**. MODELS: 1991 - **1995** (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Some vehicles may exhibit a tendency to drift left. Road surfaces have significant effect on drift tendencies. DIAGNOSIS: Test drive the vehicle on a road surface that slopes down to the right. On lanes that slope down to the right, the vehicle should track with little or no drift. On lanes that slope down to the left, a slight drift to the left is expected and normal. If the vehicle exhibits a tendency to drift left while in lanes that slope to the right, the following diagnostic procedures should be followed: A. Cross switch the front tire/wheel assemblies and re-evaluate the vehicle. If the drift is corrected, return the vehicle to the customer. If the drift to the left becomes worse, return the tire/wheel assemblies to their original positions and perform step B of the diagnosis. If the drift to the left is unchanged, perform step B of the diagnosis. B. Check and adjust as necessary, the front alignment to the following preferred specifications: Camber: 0.3 degree positive Toe: 0.1 degree in. If the vehicle still drifts left while in lanes that slope to the right, perform the repair procedure. PARTS REQUIRED: 1 6502553 Screw and Washer Assembly REPAIR PROCEDURE: This bulletin involves repositioning the front crossmember. 1. Raise the vehicle on a hoist that leaves the front wheels unsupported. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 220794 > Oct > 94 > Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left > Page 8160 2. Remove the left rear nut and shouldered stud attaching the front crossmember to the frame structure (Refer to the Illustration). 3. Install and finger tighten screw and washer assembly, P/N 6502553, at the left rear attachment position of the front crossmember. 4. Loosen the two front and right rear front crossmember attachments. 5. Using an appropriate pry bar at the left side of the front crossmember, rotate the front crossmember assembly forward using the right rear attachment as the pivot point for the rotation (looking at the front crossmember from underneath the vehicle, this will be a counterclockwise rotation). Rotate the crossmember until it contacts the left rear crossmember fastener. 6. Torque the four front crossmember fasteners to 110 ft.lbs. while the crossmember's position is held against the left rear fastener. 7. Check and adjust as necessary, the front alignment to the following preferred specifications: Camber: 0.3 degree positive Toe: 0.1 degree in. **8. If the vehicle still exhibits a left lead condition, contact your zone office for further assistance.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 02-00-01-95 (Includes Alignment) 1.0 Hrs. FAILURE CODE: **LL - Leads Left** Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 220794 > Oct > 94 > Crossmember/Alignment/Wheels/Tires - Vehicle Drifts Left > Page 8166 2. Remove the left rear nut and shouldered stud attaching the front crossmember to the frame structure (Refer to the Illustration). 3. Install and finger tighten screw and washer assembly, P/N 6502553, at the left rear attachment position of the front crossmember. 4. Loosen the two front and right rear front crossmember attachments. 5. Using an appropriate pry bar at the left side of the front crossmember, rotate the front crossmember assembly forward using the right rear attachment as the pivot point for the rotation (looking at the front crossmember from underneath the vehicle, this will be a counterclockwise rotation). Rotate the crossmember until it contacts the left rear crossmember fastener. 6. Torque the four front crossmember fasteners to 110 ft.lbs. while the crossmember's position is held against the left rear fastener. 7. Check and adjust as necessary, the front alignment to the following preferred specifications: Camber: 0.3 degree positive Toe: 0.1 degree in. **8. If the vehicle still exhibits a left lead condition, contact your zone office for further assistance.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 02-00-01-95 (Includes Alignment) 1.0 Hrs. FAILURE CODE: **LL - Leads Left** Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 8167 Cruise Control Switch: Testing and Inspection 1. Disconnect the blade type four wire electrical connector from base of steering column. 2. Using a continuity tester, or an ohmmeter, check for continuity at connector wires. Do not use a test light. Fig. 108 Speed Control Continuity Chart Fig. 8 Speed Control Connector Terminal Identification 3. Results should be obtained according to the chart. If these results are not obtained, replace switch. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 8168 Cruise Control Switch: Service and Repair 1. Disconnect battery ground cable. 2. Turn ignition switch to the Off position. 3. Remove two screws from back of steering wheel. 4. Rock switch away from air bag or horn pad while lifting switch from steering wheel. 5. Disconnect four-way electrical connector. 6. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 8177 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 8183 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 8192 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 8198 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Technical Service Bulletins > Customer Interest for ABS Light: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously ABS Light: Customer Interest ABS - Warning Light ON Continuously NO: 05-22-94 GROUP: Brakes EFFECTIVE DATE: Dec. 2, 1994 SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor Connector MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) SYMPTOM/CONDITION: Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles brake system will perform as a non-ABS equipped vehicle normally would during this condition. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair as necessary. If an ABS wheel speed sensor DTC is discovered: 1. Disconnect the 2 way connector of the suspect wheel speed sensor. 2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body harness connector. There should be resistance/interference felt between the male and female terminals. 3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic Procedures for further diagnostics. 4. If no resistance/interference is felt at one or both terminals, perform the repair procedure. PARTS REQUIRED: 1 4797997 Kit, Terminal Repair Kit Consists Of: 1 4625196 Terminal, Male 1 Connector/Wire Assembly 2 4778570 Tube, Heat Shrink REPAIR PROCEDURE: This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread female terminals. 1. Cut off the suspect body harness connector and discard. 2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and the new connector/wire assembly. 3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and spread the strands of the wire. 4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands together with the strands prepared in step 3 and twist together. 5. Solder the wires together with ROSIN core solder. 6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 7. Repeat steps 3 - 6 for the other wires. 8. Connect the body harness to the wheel speed sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Technical Service Bulletins > Customer Interest for ABS Light: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously > Page 8208 9. Test drive the vehicle and verify proper operation of the ABS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-18-97 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Technical Service Bulletins > All Technical Service Bulletins for ABS Light: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously ABS Light: All Technical Service Bulletins ABS - Warning Light ON Continuously NO: 05-22-94 GROUP: Brakes EFFECTIVE DATE: Dec. 2, 1994 SUBJECT: Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor Connector MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) SYMPTOM/CONDITION: Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles brake system will perform as a non-ABS equipped vehicle normally would during this condition. DIAGNOSIS: Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair as necessary. If an ABS wheel speed sensor DTC is discovered: 1. Disconnect the 2 way connector of the suspect wheel speed sensor. 2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body harness connector. There should be resistance/interference felt between the male and female terminals. 3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic Procedures for further diagnostics. 4. If no resistance/interference is felt at one or both terminals, perform the repair procedure. PARTS REQUIRED: 1 4797997 Kit, Terminal Repair Kit Consists Of: 1 4625196 Terminal, Male 1 Connector/Wire Assembly 2 4778570 Tube, Heat Shrink REPAIR PROCEDURE: This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread female terminals. 1. Cut off the suspect body harness connector and discard. 2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and the new connector/wire assembly. 3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and spread the strands of the wire. 4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands together with the strands prepared in step 3 and twist together. 5. Solder the wires together with ROSIN core solder. 6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 7. Repeat steps 3 - 6 for the other wires. 8. Connect the body harness to the wheel speed sensor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Technical Service Bulletins > All Technical Service Bulletins for ABS Light: > 052294 > Dec > 94 > ABS - Warning Light ON Continuously > Page 8214 9. Test drive the vehicle and verify proper operation of the ABS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-14-18-97 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Technical Service Bulletins > Page 8215 ABS Light: Description and Operation The ABS warning lamp will normally illuminate for one to two seconds when the ignition switch is first turned to the On position. Any time the Controller Anti-Lock Brake (CAB) detects a condition which results in a shutdown of the ABS function (other than when the ignition switch is first turned to the On position), it will activate the ABS warning lamp. When the lamp is on, only the anti-lock function of the brake system is affected. The base brake system and ability to stop the vehicle will not be affected. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation Brake Warning Indicator: Description and Operation The brake warning light is designed to light only when either: The parking brake is applied with the ignition key turned "ON". - One of the two service brake systems has failed. Bulb Check The instrument panel bulb can be checked each time the ignition switch is turned to the start position or the parking brake is set. Pressure Differential Warning Light Switch Purpose The function of the Pressure Differential Switch is to alert the driver to a malfunction in the brake system. Operation The hydraulic brake system is split diagonally. The left front and right rear brakes are part of one system and the right front and left rear are part of another. Both systems are routed through, but hydraulically separated by the Pressure Differential Switch. If hydraulic pressure is lost in one system, the warning light switch will activate a red light on the instrument panel, when the brake pedal is depressed. At this point the brakes require service. - However, since the brake systems are split diagonally the vehicle will retain 50% of its stopping capability in the event of a failure in either half. The warning light switch is the latching type. It will automatically recenter itself after the repair is made and the brake pedal Is depressed. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Locations Fig. 1 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Diagrams > Diagram Information and Instructions Check Gauges Lamp: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8224 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8225 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8226 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8227 Check Gauges Lamp: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8228 Fig. 1 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8229 Test 12D Repairing The Electro/Mechanical Cluster "NO RESPONSE" Condition Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions Compass: Technical Service Bulletins Instruments - Calibration/Diagnostics Revisions NUMBER: 08-78-94 GROUP: Electrical DATE: Dec. 30, 1994 REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** Models: 1994 Town & Country/Caravan/Voyager - Publication No. 81-370-4105 DESCRIPTION OF CHANGES Calibration Description & Self Diagnosis Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions > Page 8234 8C-2 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions > Page 8235 8C-4 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions > Page 8236 Compass: Technical Service Bulletins Overhead Compass/Temperature - Manual Revision NO: 08-78-94 GROUP: Electrical DATE: Dec. 30, 1994 SUBJECT: Service Manual Revision - Overhead Compass and Temperature MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) DISCUSSION: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions > Page 8237 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions > Page 8238 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions > Page 8239 This Technical Service Bulletin contains revised Service Manual pages. The revisions are marked with **ASTERISKS**. Please insert the included revised pages in the appropriate Service Manual. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions Compass: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8242 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8243 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8244 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8245 Compass: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8246 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8247 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Page 8248 Compass: Description and Operation Compass Mini-trip Module PURPOSE: The compass/mini-trip module is located in the overhead console. It displays to the driver the direction the vehicle is traveling and the current outside temperature, as well as the following traveler navigational information: average fuel economy, distance to empty (DTE), elapsed time (ET), and trip odometer (ODO). OPERATION: The information needed for the traveler functions is received over the CCD bus from the body control module. NOTE: If the compass mini-trip module has been replaced, it may be necessary to reset the calibration. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Setting Compass Variance Compass: Adjustments Setting Compass Variance DEFINITION: Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the zone map below. The number shown for your area is the variance number for your area (continued on the following page). 1. Set the Compass/Mini-Trip Console (CMTC) to compass/temperature mode. 2. Press and hold down both the US/METRIC button and the STEP button for 5 seconds. NOTE: If the buttons are held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number and resume normal operation. NOTE: Do not attach any magnetic device such as a magnetic CB antenna to the vehicle. This can cause the compass to give false readings. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Setting Compass Variance > Page 8251 Compass: Adjustments Setting the Compass The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank, the vehicle must be demagnetized. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least ten minutes after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 8257 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming ARMING 1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate SRS system is functioning correctly. 5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air Bag Systems/Testing and Inspection. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8262 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8263 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8264 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8265 Dimmer Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8266 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions Door/Trunk Ajar Indicator/Lamp: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8272 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8273 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8274 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8275 Door/Trunk Ajar Indicator/Lamp: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8276 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly Door Switch: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 8285 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly Door Switch: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly > Page 8291 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Component Locations > Page 8294 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions Driver/Vehicle Information Display: Technical Service Bulletins Instruments Calibration/Diagnostics Revisions NUMBER: 08-78-94 GROUP: Electrical DATE: Dec. 30, 1994 REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** Models: 1994 Town & Country/Caravan/Voyager - Publication No. 81-370-4105 DESCRIPTION OF CHANGES Calibration Description & Self Diagnosis Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions > Page 8299 8C-2 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - Calibration/Diagnostics Revisions > Page 8300 8C-4 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8303 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8304 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8305 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8306 Driver/Vehicle Information Display: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8307 Warning Lamp Center Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8308 Driver/Vehicle Information Display: Electrical Diagrams Electronic Vehicle Info. Center (EVIC) W/ Transmission Control (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8309 Electronic Vehicle Info. Center (EVIC) W/ Transmission Control (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8310 Warning Lamp Center (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8311 Warning Lamp Center (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Page 8312 Driver/Vehicle Information Display: Service and Repair 1. Remove instrument panel cluster bezel and left panel silencer, then disconnect parking brake linkage. 2. Remove five cover attaching screws and lower cover, then disconnect all wire connectors. 3. Remove steering column covers, then remove four cluster screws. 4. On models with electronic instruments, proceed as follows: a. Remove four cluster securing screws and four mask housing screws b. Rotate mask down, then disconnect buttons and PRNDL indicator. Fig. 9 Mechanical Instrument Cluster Removal 5. On models with mechanical instruments, rotate cluster and disconnect connector. 6. On all models, remove two transmission indicator screws and cluster. 7. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Service Reminder Indicator Light <--> [Emissions Maintenance Light] > Component Information > Description and Operation Service Reminder Indicator Light: Description and Operation This Emission Maintenance Reminder System is incorporated into the engine controller. The controller stores vehicle mileage into its memory every 8 miles, then at 60,000, 82,500 or 120,000 miles it will illuminate the Emission Maintenance Reminder (EMR) lamp. When the indicated mileage is reached or the EMR lamp is on at all times, the following parts must be replaced and the EMR lamp reset. After necessary emission maintenance has been performed, connect Diagnosis Read-Out Box II (DRB II) to the on-board diagnosis connector. Follow instructions indicated by DRB II tool. 1. At 60,00 miles, proceed as follows: a. Replace EGR valve. b. Clean EGR passage. c. Replace PCV valve. 2. At 82,500 miles, proceed as follows: a. Replace oxygen sensor. 3. At 120,000 miles, proceed as follows: a. Replace EGR valve. b. Clean EGR passage. c. Replace PCV valve. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8320 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8321 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8322 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8323 Fuel Gauge Sender: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8324 Fuel Pump System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Page 8325 Fuel Gauge Sender: Description and Operation Fuel Pump MODULE And Connector TYPICAL The fuel level sensor is a variable resistor, whose resistance changes as the level of fuel in the tank change. As the level float arm moves, the wiper on the sensor moves along the trace, either closer to or further away from, the sensor signal terminal. The further away the sensor pickup is, the higher the resistance across the sensor is. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Page 8326 Fuel Gauge Sender: Testing and Inspection SENDING UNIT TEST NOTE: When a problem occurs with a cluster gauge -- before disassembling the cluster to check the gauge -- check for a defective sending unit, sending unit wiring, or body control module. Sending units and wiring can be checked by grounding the connector leads at the sending unit. With the ignition ON grounding the the sending unit wire will cause the fuel or temperature gauge to read at or above maximum. (For fuel sending units this is the center terminal of the Fuel pump module connector.) The following procedure tests the resistance of the level sensor. It does not test the sensor circuit. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fluid level changes. 1. To test the level sensor connect an ohmmeter between the sensor signal terminal and the ground terminal of the fuel pump module connector. (The middle terminal and the terminal farthest away from the middle terminal.) 2. Move the float lever to the full position and empty position and note the resistance at both points. 3. Replace the sensor if the resistance is not within the specified values. - Sensor Full Position 8 ohms maximum - Sensor Empty Position 96.5 - 108.0 ohms Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Page 8327 Fuel Gauge Sender: Service and Repair Fuel level sensor replacement procedure is included in Fuel Pump Module service. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least ten minutes after disconnecting battery ground cable before performing any further repairs on vehicle. The SRS system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 8333 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming ARMING 1. Connect battery ground cable. 2. On models without passenger air bag, from PASSENGER side of vehicle, turn ignition switch to ON position. 3. On models with passenger air bag, ensure no one is inside vehicle when battery is connected. 4. The Supplemental Restraint System (SRS) warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate SRS system is functioning correctly. 5. If air bag warning light fails to light, or goes on and stays on, there is a system fault. Refer to Air Bag Systems/Testing and Inspection. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions Instrument Panel Circuit Board: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 8338 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 8339 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 8340 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 8341 Instrument Panel Circuit Board: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 8342 Instrument Panel Circuit Board: Electrical Diagrams Mechanical Cluster Printed Circuit Board Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 8343 Printed Circuit Board Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Locations Malfunction Indicator Lamp: Locations NOTE: MIL previously called Check Engine Lamp (CEL). Light in instrument panel. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Locations > Page 8347 Malfunction Indicator Lamp: Description and Operation NOTE: Malfunction Indicator Lamp (MIL), previously called Check Engine Lamp (CEL). PURPOSE Indicates immediate service of engine control system is required. Informs driver that he has entered "Limp-In" mode, lamp ON while vehicle is being driven. Displays Diagnostic Trouble Codes (DTC's), stored in memory. OPERATION Illuminates for three seconds when ignition switch is turned ON, (for bulb test). Illuminates if Powertrain Control Module (PCM) receives an out of range input from a monitored circuit, or, (for vehicles with California emissions), from an emission related device. - Signals that can set Malfunction Indicator Lamp are battery voltage input, charging system, Manifold Absolute Pressure (MAP), sensor, Throttle Position Sensor (TPS), Engine Coolant Temperature (ECT) sensor. Can be used to display any DTC's stored in memory, SEE POWERTRAIN MANAGEMENT/COMPUTERS AND CONTROL SYSTEMS/TESTING AND INSPECTION. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8356 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8357 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8358 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8359 Oil Pressure Sender: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8360 Engine Oil Pressure & Temp. System With Transmission Control Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Technical Service Bulletins > Overhead Compass/Temperature - Manual Revision Outside Temperature Display: Technical Service Bulletins Overhead Compass/Temperature Manual Revision NO: 08-78-94 GROUP: Electrical DATE: Dec. 30, 1994 SUBJECT: Service Manual Revision - Overhead Compass and Temperature MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) DISCUSSION: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Technical Service Bulletins > Overhead Compass/Temperature - Manual Revision > Page 8365 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Technical Service Bulletins > Overhead Compass/Temperature - Manual Revision > Page 8366 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Technical Service Bulletins > Overhead Compass/Temperature - Manual Revision > Page 8367 This Technical Service Bulletin contains revised Service Manual pages. The revisions are marked with **ASTERISKS**. Please insert the included revised pages in the appropriate Service Manual. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Speedometer Module: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 8377 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 8378 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Speedometer Module: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 8384 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 8385 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8391 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8392 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8393 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8394 Dimmer Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8395 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly Door Switch: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 8404 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly Door Switch: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 8410 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Component Locations > Page 8413 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8418 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8419 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8420 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8421 Fuel Gauge Sender: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8422 Fuel Pump System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 8423 Fuel Gauge Sender: Description and Operation Fuel Pump MODULE And Connector TYPICAL The fuel level sensor is a variable resistor, whose resistance changes as the level of fuel in the tank change. As the level float arm moves, the wiper on the sensor moves along the trace, either closer to or further away from, the sensor signal terminal. The further away the sensor pickup is, the higher the resistance across the sensor is. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 8424 Fuel Gauge Sender: Testing and Inspection SENDING UNIT TEST NOTE: When a problem occurs with a cluster gauge -- before disassembling the cluster to check the gauge -- check for a defective sending unit, sending unit wiring, or body control module. Sending units and wiring can be checked by grounding the connector leads at the sending unit. With the ignition ON grounding the the sending unit wire will cause the fuel or temperature gauge to read at or above maximum. (For fuel sending units this is the center terminal of the Fuel pump module connector.) The following procedure tests the resistance of the level sensor. It does not test the sensor circuit. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fluid level changes. 1. To test the level sensor connect an ohmmeter between the sensor signal terminal and the ground terminal of the fuel pump module connector. (The middle terminal and the terminal farthest away from the middle terminal.) 2. Move the float lever to the full position and empty position and note the resistance at both points. 3. Replace the sensor if the resistance is not within the specified values. - Sensor Full Position 8 ohms maximum - Sensor Empty Position 96.5 - 108.0 ohms Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 8425 Fuel Gauge Sender: Service and Repair Fuel level sensor replacement procedure is included in Fuel Pump Module service. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Testing and Inspection Speedometer Head: Testing and Inspection Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Controller/Testing and Inspection To diagnose and test gauge cluster, a DRB tester (scan tool) must be used. Refer to the DRB user's manual for diagnostic procedures. This vehicle is equipped with an electronically driven speedometer and odometer which has the same appearance as a conventional cable driven unit. The speedometer cable is replaced by a transmission mounted speed sensor. For diagnosis of the speed sensor refer to: Transmission and Drivetrain / Transmission Control Systems / Transmission Speed Sensor. See: Powertrain Management/Transmission Control Systems/Sensors and Switches - Transmission and Drivetrain/Sensors and Switches - A/T/Transmission Speed Sensor/Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 080794B > Dec > 94 > A/T Harsh Shift At Low Speed/Speedo. Fluctuates Speedometer Module: Customer Interest A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 080794B > Dec > 94 > A/T Harsh Shift At Low Speed/Speedo. Fluctuates > Page 8437 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 080794B > Dec > 94 > A/T Harsh Shift At Low Speed/Speedo. Fluctuates > Page 8438 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates Speedometer Module: All Technical Service Bulletins A/T - Harsh Shift At Low Speed/Speedo. Fluctuates NO: 08-07-94 Rev. B GROUP: Electrical DATE: Dec. 16, 1994 SUBJECT: Harsh Shifting at Low Speed and/or Digital Speedometer Fluctuates at Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-07-94 REV. A DATED OCT. 21, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION CLARIFIES THE SYMPTOMS, CHANGES THE DIAGNOSIS PROCEDURE, ADDS A NOTE TO THE REPAIR PROCEDURE AND PROVIDES A VEHICLE CLEAN POINT. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1993 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSMISSION AND A 3.3L OR 3.8L ENGINE **AND BUILT PRIOR TO NOV. 1, 1994, MDH 11-11-XX.** SYMPTOM/CONDITION: **The transmission may have inconsistent shift quality at vehicle speeds less than 10 MPH. Harsh 1-2 up shifts or 2-1 coast down shifts can randomly occur, usually 5-10% of the time. As spark plug wires age, harsh shifting may become more frequent. Also, the DIGITAL speedometer may fluctuate slightly (2 MPH) while the vehicle is parked and the engine is at idle**. These symptoms can be the result of induced voltage between the spark plug wires and the output speed sensor wires. No Diagnostic Trouble Codes (DTC's) are set due to the condition. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB II/III), verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary before proceeding. If the fluctuating speedometer and/or harsh transmission shift condition is not corrected after repair of any or all DTC'S, continue the diagnosis as follows: If using the MDS, select EATX State Display/Special Test/RPM Display, then monitor the Output Speed Sensor. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output speed sensor display does not remain at zero, perform the repair procedure. If using the DRB II/III, select Transmission Systems/(41TE/State Display DRB II only)/Monitors/RPM Display, then monitor Output RPM. With the transmission in **any drive gear and the parking brake and service brakes fully applied (DO NOT ALLOW THE VEHICLE TO MOVE)**, vary the engine speed slowly from idle to 1800 RPM **(DO NOT PERFORM THIS TEST FOR MORE THAN 10 SECONDS AT A TIME)**. If the output RPM does not remain at zero, perform the repair procedure. PARTS REQUIRED: 1 6004514 Clip Strap AR 6015756 Tie Strap AR 4778138 Black Tape MS-CH71A (3/4 in. x 100 ft. roll) AR 4688708 Aluminum Tape (1 in. x 60 yd. roll) REPAIR PROCEDURE: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 8444 This procedure involves covering the wiring harness near the spark plug wires with aluminum tape to prevent the spark plug wires from inducing false signals into the output speed sensor wiring that connects to the Transmission Control Module (TCM). 1. Remove and discard the tie strap holding the wiring harness to the right engine mount. 2. Remove the wiring clip from the spark plug cable separator bracket and wiring harness. On some 1993 model vehicles, the wiring may be held to the bracket with a tie strap. If so equipped, remove and discard the tie strap. 3. Remove the wiring clip from the oil dipstick by opening the clip. Do Not remove the clip from the wiring harness or otherwise damage the clip. 4. Wrap the wiring harness (over the convolute) with aluminum tape, P/N 4688708, using a 25% overlap. Wrap the wiring harness from the oil dipstick clip to within 4 in. (100 mm) of the clip at the right engine mount. **NOTE: THE TAPES MUST BE APPLIED AS DESCRIBED FOR THE REPAIR TO BE EFFECTIVE.** 5. Cover the aluminum tape **using a 25% overlap** with black tape MS-CH71A, P/N 4778138. **Triple wrap the harness in the area of the A/C compressor high pressure relief valve.** 6. Re-install the wiring harness and clip at the dip stick. 7. Install a tie strap, P/N 6015756, at the right engine mount with the tie strap going through the wiring clip and through the outboard horizontal hole in the engine mount bracket. 8. Install a clip strap, P/N 6004514, to the engine wiring harness at the spark plug cable separator bracket and plug it onto the bracket. If the vehicle originally had the wiring strapped to the spark plug separator bracket, replace the tie strap. **9. Position the spark plug cables to provide the maximum distance away from the transmission wiring harness.** 10. Repeat the diagnostic procedure to confirm proper Output Speed Sensor/Output RPM values. NOTE: IF HARSH SHIFTING CONTINUES TO EXIST, REFER TO TECHNICAL SERVICE BULLETIN **18-27-94 ISSUED IN THE DEC. 30, 1994 COMPAK.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-90-66-98 0.3 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 080794B > Dec > 94 > A/T - Harsh Shift At Low Speed/Speedo. Fluctuates > Page 8445 FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions Temperature Sensor (Gauge): Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 8451 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 8452 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 8453 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 8454 Temperature Sensor (Gauge): Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and Instructions > Page 8455 Engine Oil Pressure & Temp. System With Transmission Control Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Diagrams > Page 8456 Temperature Sensor (Gauge): Testing and Inspection When a malfunction occurs with a cluster gauge, before disassembling the cluster to check the gauge, check for a defective sending unit or wiring as follows: 1. Ground sending unit connector leads, at the sending unit, in the vehicle. 2. With ignition in ON position, a grounded input will cause the fuel or temperature gauge to read maximum or above. Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Controller/Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Back-Up Light <--> [Backup Lamp] > Backup Lamp Relay > Component Information > Locations Backup Lamp Relay: Locations In Power Distribution Center The Backup Lamp Relay is located in the Power Distribution Box. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Back-Up Light <--> [Backup Lamp] > Backup Lamp Relay > Component Information > Locations > Page 8462 Power Distribution Center As shown, the Backup Lamp Relay is in the bottom row center. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Back-Up Light <--> [Backup Lamp] > Backup Lamp Relay > Component Information > Locations > Page 8463 Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Back-Up Light <--> [Backup Lamp] > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Back-Up Light <--> [Backup Lamp] > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8468 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Back-Up Light <--> [Backup Lamp] > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8469 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Back-Up Light <--> [Backup Lamp] > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8470 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Back-Up Light <--> [Backup Lamp] > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8471 Backup Lamp Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Stop Light Switch - Wiring Connector Service Stop Lamp Switch: Technical Service Bulletins Stop Light Switch - Wiring Connector Service NO.: 08-67-93 GROUP: Electrical DATE: Dec. 31, 1993 SUBJECT: Stop Light Switch Wiring Connector Service MODELS: 1995 (PL) Neon 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1994 (AJ) LeBaron Convertible 1994 (AP) Shadow/Sundance 1994 (AS) Caravan/Voyager/Town & Country 1994 (BR) Ram Pickup 1994 (LH) Concorde/Intrepid/Vision 1994 (LH) LHS/New Yorker 1994 (ZJ) Grand Cherokee SYMPTOM/CONDITION: When servicing the stop light switch or wiring connector, the stop light switch wiring connector may be difficult to remove from stop light switch. Attempts to remove the wiring connector may damage the insulator wedge or the switch itself. REPAIR PROCEDURE: This bulletin involves removing the stop light switch with wiring connector attached as an assembly before disconnecting the wiring connector. 1. Remove the stop light switch, with wiring connector still attached to the switch, by turning the switch counterclockwise 1/16 turn and pulling straight out of the mounting bracket. 2. Depress and hold down both locking tabs on the "blue" wiring insulator wedge and pull the wiring connector from the stop light switch insulator, Figure 1. NOTE: DISCONNECTING THE WIRING CONNECTOR HARNESS FROM THE SWITCH BY PULLING ON THE WIRING MAY RESULT IN OPEN CIRCUITS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Stop Light Switch - Wiring Connector Service > Page 8476 3. To remove the "blue" wedge insert a small screwdriver between the top of the wiring connector insulator and the wedge and prying up while pushing the wedge out towards the wire harness, Figure 2. 4. To reinstall the wiring harness connector into the stop light switch, reinstall the connector wedge into the connector, then insert the wiring harness connector into the stop light switch assembly and finally install the stop lamp switch assembly into the mounting bracket and secure it by rotating the switch clockwise approximately 1/16 of a turn. If a new stop light switch is being installed, follow the adjustment procedure in the appropriate service manual. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Page 8477 Stop Lamp Switch: Locations Brake Switch Sensor mounted on brake pedal support bracket. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions Stop Lamp Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8480 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8481 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8482 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8483 Stop Lamp Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8484 Stop Lamp Switch: Electrical Diagrams Vehicle Speed Control & Stop Lamp Switch SH-57 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8485 Vehicle Speed Control & Stop Lamp Switch SH-58 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Page 8486 Stop Lamp Switch: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect stop light switch electrical connector, then remove switch assembly. 3. Reverse procedure to install. If switch adjustment required, proceed as follows: a. Push switch forward until fully seated. This will move brake pedal slightly forward. b. Pull brake pedal back until it will go back no further. Switch will ratchet backward into correct position. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Center High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Component Information > Diagrams > Diagram Information and Instructions Center High Mounted Stop Lamp: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Center High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Component Information > Diagrams > Diagram Information and Instructions > Page 8491 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Center High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Component Information > Diagrams > Diagram Information and Instructions > Page 8492 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Center High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Component Information > Diagrams > Diagram Information and Instructions > Page 8493 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Center High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Component Information > Diagrams > Diagram Information and Instructions > Page 8494 Center High Mounted Stop Lamp: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Center High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Component Information > Diagrams > Diagram Information and Instructions > Page 8495 Center High Mounted Stop Lamp Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions Console Lamp: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8501 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8502 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8503 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8504 Console Lamp: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8505 Console Lamp: Electrical Diagrams Headlamp Switch Controlled Interior & Console Lamps (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8506 Headlamp Switch Controlled Interior & Console Lamps (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions Daytime Running Lamp Control Unit: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8513 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8514 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8515 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8516 Daytime Running Lamp Control Unit: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8517 Daytime Running Lamp Module Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8518 Daytime Running Lamp Control Unit: Electrical Diagrams Daytime Running Lamp Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8519 Fog Lamp System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8524 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8525 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8526 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8527 Dimmer Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8528 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions Dome Lamp: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8533 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8534 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8535 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8536 Dome Lamp: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8537 Dome Lamp: Connector Views Dome To Instrument Panel Wiring Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8538 Instrument Panel To Dome Wiring Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8539 Dome Lamp: Electrical Diagrams Dome And Courtesy Lamps (Part 1 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8540 Dome And Courtesy Lamps (Part 2 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8541 Dome And Courtesy Lamps (Part 3 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8542 Dome And Courtesy Lamps (Part 4 Of 4) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly Door Switch: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 8551 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly Door Switch: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 8557 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Switch: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor Evaporator Drain Tube: All Technical Service Bulletins Air Conditioning Ducts - Emits Musty Odor NO: 24-06-95 Rev. A GROUP: Heater & A/C DATE: May 26, 1995 SUBJECT: Air Conditioning Ducts Emit Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 DATED MAY 5, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE LABOR OPERATION NUMBERS HAVE BEEN CORRECTED. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1994 - 1995 (AB) Ram Van/Wagon (Built On or After Aug. 1, 1993 - MDH 08-01-XX) 1992 - 1993 (AC) Dynasty/New Yorker Salon (Built On or After Jan. 31, 1992 - MDH 01-31 -XX) 1993 - 1995 (AN) Dakota 1992 - 1995 (AS) Caravan/Voyager/Town & Country 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue (Built On or After Jan. 31, 1992 - MDH 01-31-XX) 1994 - 1995 (BR) Ram Truck 1995 (JA) Cirrus/Stratus 1993 - 1995 (LH) Concord/Intrepid/LHS/New Yorker/Vision 1995 (PL) Neon 1993 - 1995 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicles may emit a "musty" odor from the air conditioning ducts. The odor is most noticeable when the A/C system is first turned on. Two causes for A/C related odors are possible, and are covered separately below: CAUSE AND CORRECTION - VEHICLES IN SERVICE LESS THAN 12 MONTHS On some vehicles with "plate fin" A/C evaporators, the manufacturing process occasionally results in an excessive amount of corrosion protection coating being applied on the evaporator external surfaces. A heavy coating can result in an odor from the evaporator fins, especially when dry fins become wet from condensation. A new coating has been developed to correct this condition. The evaporator coil in the A/C unit must be replaced. Proceed to Repair Procedure A. CAUSE AND CORRECTION - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE Offensive odors from air conditioners can sometimes occur in vehicles that have been in extended use resulting from possible accumulation of "foreign matter" in the AC unit. This condition is more likely to occur in vehicles that have been in extended use in humid climates. To correct this condition, the internal surfaces of the A/C air handling system will have to be cleaned. Proceed to Repair Procedure B. PARTS AND EQUIPMENT REQUIRED: REPAIR PROCEDURE A - VEHICLES IN SERVICE LESS THAN 12 MONTHS AR 4798625 Coil, A/C Evaporator (AB 1994-1995, Vehicles Built On or After Aug. 1,1993) AR 4677011 Coil, A/C Evaporator (AC/AY 1992-1993, Vehicles Built On or After Jan. 31,1992) AR 4798624 Coil, A/C Evaporator (AN 1993-1995) AR 4723069 Coil, A/C Evaporator (AS 1992) AR 4734292 Coil, A/C Evaporator (AS 1993-1994) AR 4797131 Coil, A/C Evaporator (AS 1995) AR 4723518 Coil, A/C Evaporator (BR 1994) AR 4798705 Coil, A/C Evaporator (BR 1995) AR 4644790 Coil, A/C Evaporator (JA 1995) AR 4797129 Coil, A/C Evaporator (LH 1993-1995) AR 4797130 Coil, A/C Evaporator (PL 1995) AR 4723518 Coil, A/C Evaporator (ZJ 1993-1994) AR 4798705 Coil, A/C Evaporator (ZJ 1995) REPAIR PROCEDURE B - VEHICLES IN SERVICE FOR 12 MONTHS OR MORE 1 4728942 A/C Evaporator Cleaner 1 4740319 Reusable Applicator 1 NPN Pair of Rubber Gloves 1 NPN Pair of Safety Glasses REPAIR PROCEDURE A: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Switch: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 8563 This repair involves checking the A/C condensation drain tube for proper operation and replacing the A/C evaporator coil. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. 2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts and Equipment Required section. Follow all evaporator removal and replacement instructions listed in the appropriate vehicle Service Manual. REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper operation and cleaning and disinfecting the A/C evaporator coil and housing. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. NOTE: FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE WATER TO FLUSH EYES IF NECESSARY 2. Protect the interior of the vehicle with a drop cloth. 3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the evaporator coil. NOTE: FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM. 4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the dash panel). Open the vehicle doors. On AS Body models, remove the resistor block. NOTE: ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT. 6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319. 7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty. Spray into the resistor block opening on "AS" models. 8. Turn the vehicle OFF and allow to soak for at least 30 minutes. 9. Wipe off any excess cleaner from around the instrument panel ducts. 10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle for 20 minutes to dry the system. NOTE: FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE ODOR PROBLEM. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-95 Evaporator, Replace 1994 (AB) 2.7 Hrs. 1995 (AB) 1.9 Hrs. 1992-93 (AC/AY) 2.0 Hrs. 1993-95 (AN) 2.2 Hrs. 1992-93 (AS) 2.4 Hrs. 1994-95 (AS) 3.8 Hrs. 1994-95 (BR) 3.3 Hrs. **1995 (JA) 3.7 Hrs.** 1993 (LH) 4.1 Hrs. 1994-95 (LH) 3.4 Hrs. 1995 (PL) 3.9 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Switch: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 8564 1993-95 (ZJ) 3.1 Hrs. Optional Equipment 24-65-02-60 Console Equipped 1992-93 (AS) 0.2 Hrs. 1993-95 (LH) 0.2 Hrs. 24-65-02-66 50/50 Bench Seat 1993-95 (LH) 0.8 Hrs. FAILURE CODE: P8 - New Part **24-65-02-94** Evaporator, Clean and Disinfect 0.7 Hrs. FAILURE CODE: YP - Odor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Switch: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 8570 This repair involves checking the A/C condensation drain tube for proper operation and replacing the A/C evaporator coil. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. 2. Replace the A/C evaporator coil with the appropriate evaporator coil as called out in the Parts and Equipment Required section. Follow all evaporator removal and replacement instructions listed in the appropriate vehicle Service Manual. REPAIR PROCEDURE B: This repair involves checking the A/C condensation drain tube for proper operation and cleaning and disinfecting the A/C evaporator coil and housing. 1. Verify that the A/C condensation drain tube is free from any blockage and drains freely. Repair as necessary. NOTE: FOLLOW ALL CAUTIONS AND WARNINGS SUPPLIED WITH THE A/C EVAPORATOR CLEANER: - WEAR SAFETY GLASSES AND GLOVES - AVOID BREATHING VAPORS - USE WATER TO FLUSH EYES IF NECESSARY 2. Protect the interior of the vehicle with a drop cloth. 3. Start the engine, set the blower on HIGH, air on RECIRCULATION, turn the A/C COMPRESSOR OFF, open all of the instrument panel ducts and vehicle windows. Run the vehicle for 60 minutes to dry out the evaporator coil. NOTE: FAILURE TO DRY THE EVAPORATOR FOR 60 MINUTES WILL NOT EFFECTIVELY PREPARE THE EVAPORATOR COIL FOR CLEANING AND WILL NOT RESOLVE THE ODOR PROBLEM. 4. Switch to OUTSIDE AIR. With a shop rag, block about 90% of the outside air inlet to increase air velocity (the outside air inlet is located outside the vehicle under the cowl on the right side of the dash panel). Open the vehicle doors. On AS Body models, remove the resistor block. NOTE: ON "AS" MODELS, THE THREADS OF THE SCREWS ATTACHING THE RESISTOR BLOCK ARE NOT FULL LENGTH. IT IS NECESSARY TO GENTLY PRY OUT THE RESISTOR BLOCK WHILE TURNING THE SCREWS COUNTERCLOCKWISE SO THE THREADS WILL ENGAGE AND COME OUT. 6. Shake the bottle of evaporator cleaner, P/N 4728942. Connect the bottle and a compressed air supply, with at least 80 PSI of pressure, to the reusable applicator, P/N 4740319. 7. Spray the cleaner into the outside air inlet for 20 seconds or until the bottle is completely empty. Spray into the resistor block opening on "AS" models. 8. Turn the vehicle OFF and allow to soak for at least 30 minutes. 9. Wipe off any excess cleaner from around the instrument panel ducts. 10. Start the engine, set the blower on HIGH, air on RECIRCULATE, turn the AC COMPRESSOR OFF, open all of the instrument panel ducts, and open all of the vehicle windows. Run the vehicle for 20 minutes to dry the system. NOTE: FAILURE TO DRY THE EVAPORATOR COIL FOR 20 MINUTES WILL NOT RESOLVE THE ODOR PROBLEM. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-95 Evaporator, Replace 1994 (AB) 2.7 Hrs. 1995 (AB) 1.9 Hrs. 1992-93 (AC/AY) 2.0 Hrs. 1993-95 (AN) 2.2 Hrs. 1992-93 (AS) 2.4 Hrs. 1994-95 (AS) 3.8 Hrs. 1994-95 (BR) 3.3 Hrs. **1995 (JA) 3.7 Hrs.** 1993 (LH) 4.1 Hrs. 1994-95 (LH) 3.4 Hrs. 1995 (PL) 3.9 Hrs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Switch: > 240695A > May > 95 > Air Conditioning Ducts - Emits Musty Odor > Page 8571 1993-95 (ZJ) 3.1 Hrs. Optional Equipment 24-65-02-60 Console Equipped 1992-93 (AS) 0.2 Hrs. 1993-95 (LH) 0.2 Hrs. 24-65-02-66 50/50 Bench Seat 1993-95 (LH) 0.8 Hrs. FAILURE CODE: P8 - New Part **24-65-02-94** Evaporator, Clean and Disinfect 0.7 Hrs. FAILURE CODE: YP - Odor Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 8574 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Fog Lamp <--> [Fog/Driving Lamp] > Fog/Driving Lamp Relay > Component Information > Locations Micro Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Flasher: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8587 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8588 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8589 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8590 Hazard Warning Flasher: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8591 Stop/Turn & Hazard Flasher Systems Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams Multi-Function Switch Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions Headlight Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8600 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8601 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8602 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8603 Headlight Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8604 Headlight Switch: Connector Views Headlamp Switch Connector (Part 1 Of 3) Headlamp Switch Connector (Part 2 Of 3) Headlamp Switch Connector (Part 3 Of 3) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8605 Headlight Switch: Electrical Diagrams Headlamp Switch (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8606 Headlamp Switch (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 8607 Headlight Switch: Service and Repair The headlamp switch is part of the left pod switch assembly. 1. Fabricate a 3/16 inch diameter metal rod approximately 10 inches long. Bend 1 1/2 inches on both ends 90°. 2. Place fabricated tool in hole right of switch in cluster bezel below the pod switch assembly, then depress lower tab and pull switch free of lower tab. 3. Move tool upward right side of switch to top tab, then pull tab down and pull switch out of bezel. 4. Disconnect wire connector. 5. To install, connect wire connector and push switch into until tabs lock. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Relay > Component Information > Locations Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Diagrams Multi-Function Switch Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions Key Cylinder Lamp: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8622 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8623 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8624 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8625 Key Cylinder Lamp: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8626 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations Backup Lamp Relay: Locations In Power Distribution Center The Backup Lamp Relay is located in the Power Distribution Box. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 8635 Power Distribution Center As shown, the Backup Lamp Relay is in the bottom row center. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 8636 Power Distribution Center Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions Daytime Running Lamp Control Unit: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8642 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8643 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8644 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8645 Daytime Running Lamp Control Unit: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8646 Daytime Running Lamp Module Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8647 Daytime Running Lamp Control Unit: Electrical Diagrams Daytime Running Lamp Module Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 8648 Fog Lamp System Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Micro Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Low Beam Relay > Component Information > Locations Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations Turn Signal Relay: Locations Relay Block Combination flasher relay plugs into the lower left corner of the relay bank located to the left of the fuse block. Remove the lower steering wheel column cover for access. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8672 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8673 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8674 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8675 Backup Lamp Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Stop Light Switch - Wiring Connector Service Stop Lamp Switch: Technical Service Bulletins Stop Light Switch - Wiring Connector Service NO.: 08-67-93 GROUP: Electrical DATE: Dec. 31, 1993 SUBJECT: Stop Light Switch Wiring Connector Service MODELS: 1995 (PL) Neon 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1994 (AJ) LeBaron Convertible 1994 (AP) Shadow/Sundance 1994 (AS) Caravan/Voyager/Town & Country 1994 (BR) Ram Pickup 1994 (LH) Concorde/Intrepid/Vision 1994 (LH) LHS/New Yorker 1994 (ZJ) Grand Cherokee SYMPTOM/CONDITION: When servicing the stop light switch or wiring connector, the stop light switch wiring connector may be difficult to remove from stop light switch. Attempts to remove the wiring connector may damage the insulator wedge or the switch itself. REPAIR PROCEDURE: This bulletin involves removing the stop light switch with wiring connector attached as an assembly before disconnecting the wiring connector. 1. Remove the stop light switch, with wiring connector still attached to the switch, by turning the switch counterclockwise 1/16 turn and pulling straight out of the mounting bracket. 2. Depress and hold down both locking tabs on the "blue" wiring insulator wedge and pull the wiring connector from the stop light switch insulator, Figure 1. NOTE: DISCONNECTING THE WIRING CONNECTOR HARNESS FROM THE SWITCH BY PULLING ON THE WIRING MAY RESULT IN OPEN CIRCUITS. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Stop Light Switch - Wiring Connector Service > Page 8680 3. To remove the "blue" wedge insert a small screwdriver between the top of the wiring connector insulator and the wedge and prying up while pushing the wedge out towards the wire harness, Figure 2. 4. To reinstall the wiring harness connector into the stop light switch, reinstall the connector wedge into the connector, then insert the wiring harness connector into the stop light switch assembly and finally install the stop lamp switch assembly into the mounting bracket and secure it by rotating the switch clockwise approximately 1/16 of a turn. If a new stop light switch is being installed, follow the adjustment procedure in the appropriate service manual. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Page 8681 Stop Lamp Switch: Locations Brake Switch Sensor mounted on brake pedal support bracket. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions Stop Lamp Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8684 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8685 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8686 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8687 Stop Lamp Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8688 Stop Lamp Switch: Electrical Diagrams Vehicle Speed Control & Stop Lamp Switch SH-57 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8689 Vehicle Speed Control & Stop Lamp Switch SH-58 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Page 8690 Stop Lamp Switch: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect stop light switch electrical connector, then remove switch assembly. 3. Reverse procedure to install. If switch adjustment required, proceed as follows: a. Push switch forward until fully seated. This will move brake pedal slightly forward. b. Pull brake pedal back until it will go back no further. Switch will ratchet backward into correct position. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair Combination Switch: Service and Repair The multi-function switch includes the turn signal, headlight beam select and windshield wiper switches. If any of these switches are found defective, the entire multi-function switch must be replaced. 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever. 3. On all models, remove upper and lower steering column covers, then remove multi-function switch tamper proof mounting screws. 4. Pull switch from column and loosen connector screw, then remove connector from switch. Screw remains in connector. 5. Remove switch from the vehicle. 6. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly Door Switch: Customer Interest Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp Flickers/Locks Cycle Repeatedly > Page 8702 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly Door Switch: All Technical Service Bulletins Door Ajar Lamp - Flickers/Locks Cycle Repeatedly NO: 08-21-94 GROUP: Electrical DATE: Apr. 29, 1994 SUBJECT: Sliding Door Ajar Switch/Adjustment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-62-93 DATED DEC. 17, 1993 WHICH SHOULD BE NOTED IN YOUR FILES. THIS IS A COMPLETE REVISION THAT ADDS PARTS AND A REPAIR PROCEDURE. MODELS: 1991 - 1994 (AS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Door ajar warning lamp flickers, the power door locks, if the automatic (rolling) door lock feature is enabled, cycles repeatedly and/or a "mystery chime" from the Body Control Module (BCM) may be experienced. On 1993 and 1994 models, flickering of the courtesy lamps may also occur. NOTE: THIS REPAIR PROCEDURE IS ALSO RECOMMENDED ANY TIME AN ADJUSTMENT IS MADE TO THE SLIDING DOOR THAT MOVES THE SLIDING DOOR OUTBOARD OR AWAY FROM THE BODY C-PILLAR. PARTS REQUIRED: 1 4687558 Switch, Ajar Sliding Door 1 4688479 Bumper, Over-Slam REPAIR PROCEDURE: This bulletin involves installing an over-slam bumper to the C-Pillar and replacing the sliding door ajar switch. 1. Using the procedure outlined on Page 23-30 of the 1994 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-4105), remove the sliding door assembly. 2. Cut out the template as shown. 3. Position the template over the sliding door ajar switch and center punch the point indicated on the template. 4. Remove the template (template should be retained for future use) and drill a 13/64 in. (5.16 mm) hole at the center punched location. De-burr the hole, otherwise, the groove in over-slam bumper may not be able to engage the sheetmetal and be retained. 5. Install the over-slam bumper (P/N 4688479) with a twisting motion into the 13/64 in. hole (5.16 mm). Applying silicone the tip of the over-slam Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 082194 > Apr > 94 > Door Ajar Lamp - Flickers/Locks Cycle Repeatedly > Page 8708 bumper will ease the installation effort. 6. Re-install the sliding door and adjust as necessary. 7. Remove the sliding door ajar switch by carefully prying it out and disconnecting the wiring. 8. Connect the replacement sliding door ajar switch (P/N 4687558) to the wiring and install the switch into the C-Pillar cavity. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-80-88-91 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Component Locations > Page 8711 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Multi-Function Switch Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions Headlight Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8719 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8720 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8721 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8722 Headlight Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8723 Headlight Switch: Connector Views Headlamp Switch Connector (Part 1 Of 3) Headlamp Switch Connector (Part 2 Of 3) Headlamp Switch Connector (Part 3 Of 3) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8724 Headlight Switch: Electrical Diagrams Headlamp Switch (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 8725 Headlamp Switch (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 8726 Headlight Switch: Service and Repair The headlamp switch is part of the left pod switch assembly. 1. Fabricate a 3/16 inch diameter metal rod approximately 10 inches long. Bend 1 1/2 inches on both ends 90°. 2. Place fabricated tool in hole right of switch in cluster bezel below the pod switch assembly, then depress lower tab and pull switch free of lower tab. 3. Move tool upward right side of switch to top tab, then pull tab down and pull switch out of bezel. 4. Disconnect wire connector. 5. To install, connect wire connector and push switch into until tabs lock. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams Multi-Function Switch Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair Combination Switch: Service and Repair The multi-function switch includes the turn signal, headlight beam select and windshield wiper switches. If any of these switches are found defective, the entire multi-function switch must be replaced. 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever. 3. On all models, remove upper and lower steering column covers, then remove multi-function switch tamper proof mounting screws. 4. Pull switch from column and loosen connector screw, then remove connector from switch. Screw remains in connector. 5. Remove switch from the vehicle. 6. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations Turn Signal Relay: Locations Relay Block Combination flasher relay plugs into the lower left corner of the relay bank located to the left of the fuse block. Remove the lower steering wheel column cover for access. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Diagrams > Diagram Information and Instructions Underhood Lamp: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8741 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8742 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8743 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8744 Underhood Lamp: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8745 Underhood Lamp Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions Vanity Lamp: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8750 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8751 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8752 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8753 Vanity Lamp: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8754 Vanity Lamp: Electrical Diagrams Overhead Console W/O Mini-Trip Computer (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8755 Overhead Console W/O Mini-Trip Computer (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Heated Glass Element Relay > Component Information > Locations Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Relay Block Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8770 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8771 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8772 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8773 Power Window Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8774 Power Window Switch: Electrical Diagrams Overhead Console W/O Mini-Trip Computer (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8775 Overhead Console W/O Mini-Trip Computer (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8781 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8782 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8783 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8784 Power Window Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8785 Power Window Switch: Electrical Diagrams Overhead Console W/O Mini-Trip Computer (Part 1 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8786 Overhead Console W/O Mini-Trip Computer (Part 2 Of 2) Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair Glass Channel And Run Weatherstrip 1. Lower door glass to down position. 2. Remove side view mirror as necessary to gain clearance for weatherstrip removal. 3. Pull glass run weatherstrip from door frame channel. 4. Reverse the preceding operation for installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Manual Window Regulator Replacement Window Regulator: Service and Repair Manual Window Regulator Replacement *** THIS ARTICLE HAS BEEN UPDATED BY TSB # 23-29-93 DATED JUNE 4, 1993 Front Door Power Regulator REMOVAL 1. Remove trim panel and door liner. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 2. Remove the front door glass. See: Window Glass/Front Door Window Glass/Service and Repair 3. Remove the mounting bolts holding the manual regulator to the inner door panel. 4. Disengage the push-in fastener holding the regulator cables to the inner door panel. 5. Remove the manual window regulator from the door. INSTALLATION 1. Install the manual window regulator into the door. 2. Install the push-in fastener holding the regulator cables to the inner door panel. 3. Install the mounting bolts that hold the manual regulator to the inner door panel. 4. Install the front door glass. See: Window Glass/Front Door Window Glass/Service and Repair 5. Install the door liner and door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Manual Window Regulator Replacement > Page 8796 Window Regulator: Service and Repair Power Window Regulator Replacement *** THIS ARTICLE HAS BEEN UPDATED BY TSB # 23-29-93 DATED JUNE 4, 1993 Front Door Power Regulator REMOVAL 1. Remove trim panel and door liner. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 2. Remove the front door glass. See: Window Glass/Front Door Window Glass/Service and Repair 3. Disconnect the battery negative cable. 4. Disconnect the power window motor electrical connector. Disengage push-in fastener holding regulator wiring harness to inner door panel. 5. Remove the mounting bolts holding the power regulator to the inner door panel. 6. Disengage the push-in fastener holding the regulator cables to the inner door panel. 5. Remove the power window regulator from the door. INSTALLATION 1. Install the power window regulator into the door. 2. Install the push-in fastener holding the regulator cables to the inner door panel. 3. Install the mounting bolts that hold the power regulator to the inner door panel. 4. Connect the power window motor electrical connector and the fastener that holds the wiring harness to the inner door panel. 5. Connect the negative battery terminal. 4. Install the front door glass. See: Window Glass/Front Door Window Glass/Service and Repair 5. Install the door liner and door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair Window Track: Service and Repair Front Door Glass Lower Channel Removal Front Lower Channel And Window Regulator 1. Remove door trim panel and water shield. 2. Raise glass to up position. 3. Remove bolts holding channel to inner door panel. 4. Separate channel from door. 3. Reverse the preceding operation for installation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 236894 > Sep > 94 > Backlight/Windshield Moulding - Glue Oozing Out Windshield: Customer Interest Backlight/Windshield Moulding - Glue Oozing Out NO: 23-68-94 GROUP: Body DATE: Sep. 30, 1994 SUBJECT: Glue Oozes Out at Backlight or Windshield Molding MODELS: 1994 - 1995 (AN) Dakota 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (BR) Ram Truck 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 (JA) Cirrus/Stratus 1994 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1995 (PL) Neon SYMPTOM/CONDITION: A sticky clear to light brown material (hot melt glue) seeps out of the edge of the backlight and/or windshield molding and collects at the bottom corners of the moldings. The material could also be seeping into the trunk drain trough. The hot melt glue is used as an aid during vehicle assembly and has no effect on the structural or sealing integrity of the vehicle. After a period of time the hot melt glue reacts with the backlight and/or windshield moldings and causes the hot melt glue to melt at a lower temperature thus running down the sides of the glass to the bottom of the molding. DIAGNOSIS: Visually inspect the lower corners of the backlight and windshield moldings. If the hot melt glue is visible, perform the repair procedure. PARTS REQUIRED: AR 4318067 Solvent, Mopar Concentrated Windshield Washer REPAIR PROCEDURE: This bulletin involves removal of the hot melt glue from the backlight and/or windshield glass and molding. 1. Clean up of the glue is accomplished with Mopar Concentrated Windshield Washer Solvent, P/N 4318067. The washer solvent is an alcohol based material and dissolves the glue for easy clean up with a cloth. 2. Use a trim stick or tongue depressor covered with a cloth saturated with windshield washer concentrate to get under the molding and run along the edge of the glass to remove as much of the hot melt glue as possible. If most of the glue is not removed, the condition will reoccur. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-30-50-92 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 236894 > Sep > 94 > Backlight/Windshield Moulding - Glue Oozing Out Windshield: All Technical Service Bulletins Backlight/Windshield Moulding - Glue Oozing Out NO: 23-68-94 GROUP: Body DATE: Sep. 30, 1994 SUBJECT: Glue Oozes Out at Backlight or Windshield Molding MODELS: 1994 - 1995 (AN) Dakota 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (BR) Ram Truck 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 (JA) Cirrus/Stratus 1994 - 1995 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1995 (PL) Neon SYMPTOM/CONDITION: A sticky clear to light brown material (hot melt glue) seeps out of the edge of the backlight and/or windshield molding and collects at the bottom corners of the moldings. The material could also be seeping into the trunk drain trough. The hot melt glue is used as an aid during vehicle assembly and has no effect on the structural or sealing integrity of the vehicle. After a period of time the hot melt glue reacts with the backlight and/or windshield moldings and causes the hot melt glue to melt at a lower temperature thus running down the sides of the glass to the bottom of the molding. DIAGNOSIS: Visually inspect the lower corners of the backlight and windshield moldings. If the hot melt glue is visible, perform the repair procedure. PARTS REQUIRED: AR 4318067 Solvent, Mopar Concentrated Windshield Washer REPAIR PROCEDURE: This bulletin involves removal of the hot melt glue from the backlight and/or windshield glass and molding. 1. Clean up of the glue is accomplished with Mopar Concentrated Windshield Washer Solvent, P/N 4318067. The washer solvent is an alcohol based material and dissolves the glue for easy clean up with a cloth. 2. Use a trim stick or tongue depressor covered with a cloth saturated with windshield washer concentrate to get under the molding and run along the edge of the glass to remove as much of the hot melt glue as possible. If most of the glue is not removed, the condition will reoccur. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-30-50-92 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 232794 > Mar > 94 > Windshield/Cowl - Squeak Elimination Windshield: All Technical Service Bulletins Windshield/Cowl - Squeak Elimination NO: 23-27-94 GROUP: Body DATE: Mar. 18, 1994 SUBJECT: Squeak Noise At The Base Of The Windshield MODELS: 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: Water soluble support spacers are used in the windshield installation process at the assembly plant to properly position the windshield. During the transit and vehicle predelivery processes, if enough water does not come in contact with the windshield support spacers, they may not dissolve as intended and may cause a squeaking noise. Typically, enough water contacts the windshield support spacers during a car wash. Prior to delivering the new vehicle to the customer, look for the support spacers at both sides of the base of the windshield (refer to the illustration). If the support spacers are still in place, raise the cowl and pry them out or slowly pour two gallons of hot water directly on them until they dissolve. This will prevent the customer from experiencing a squeak condition on the new vehicle. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 232794 > Mar > 94 > Windshield/Cowl - Squeak Elimination Windshield: All Technical Service Bulletins Windshield/Cowl - Squeak Elimination NO: 23-27-94 GROUP: Body DATE: Mar. 18, 1994 SUBJECT: Squeak Noise At The Base Of The Windshield MODELS: 1994 (AS) Town & Country/Caravan/Voyager DISCUSSION: Water soluble support spacers are used in the windshield installation process at the assembly plant to properly position the windshield. During the transit and vehicle predelivery processes, if enough water does not come in contact with the windshield support spacers, they may not dissolve as intended and may cause a squeaking noise. Typically, enough water contacts the windshield support spacers during a car wash. Prior to delivering the new vehicle to the customer, look for the support spacers at both sides of the base of the windshield (refer to the illustration). If the support spacers are still in place, raise the cowl and pry them out or slowly pour two gallons of hot water directly on them until they dissolve. This will prevent the customer from experiencing a squeak condition on the new vehicle. POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions Washer Fluid Level Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8828 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8829 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8830 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8831 Washer Fluid Level Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8832 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8833 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair Windshield Washer Switch: Service and Repair The multi-function switch includes the turn signal, headlight beam select and windshield wiper switches. If any of these switches are found defective, the entire multi-function switch must be replaced. 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever. 3. On all models, remove upper and lower steering column covers, then remove multi-function switch tamper proof mounting screws. 4. Pull switch from column and loosen connector screw, then remove connector from switch. Screw remains in connector. 5. Remove switch from the vehicle. 6. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Wiper Switch: Diagrams Multi-Function Switch Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 8840 Rear Wiper Switch Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 8841 Wiper Switch: Testing and Inspection 1. Place pod switch in the Off position. Intermittent Wiper Pod Switch 2. Check for continuity between terminals A6 and A4. If continuity is not indicated, replace switch. 3. Place pod switch in the Max Delay position (left end of variable resistor). 4. Check for continuity between terminal A7 and terminals A5, A3 and B3. If continuity is not indicated, replace pod switch. 5. Check resistance between terminals A1 and B3. Resistance should measure 210,000-390,000 ohms. If not, replace the pod switch. 6. Place switch in the Min Delay position (right end of variable resistor). 7. Check for continuity between terminal A7 and terminals A5, A3 and B3. 8. Check resistance between terminals A1 and B3. Resistance should measure 350-650 ohms. 9. When the slide is moved from Max to Min Delay, or opposite. Continuity between terminal A7 and terminals A5, A3 and B3 should remain constant. If not, replace switch. 10. Resistance between terminals A1 and B3 will decrease as the control is moved from Max to Min Delay, or increase when moved from Min to Max Delay. If not, replace switch. 11. Place switch in the Lo position, then check for continuity between terminals A4 and B3. If continuity is not indicated, replace pod switch. 12. Place switch in Hi position, then check for continuity between terminals A2 and B3. If continuity is not indicated, replace switch. 13. Check for continuity between terminals B3 and B4, when the front washer button is depressed. If not, replace switch. 14. Check for continuity between terminals B2 and B5 when the rear wiper switch is in the On position (indicator lamp will illuminate only when the headlamps are on). If continuity is not indicated, replace switch. 15. Check continuity between terminals B1 and B5 when the rear washer button is depressed. If continuity is not indicated, replace the switch. 16. Two switch illuminating bulbs are fed by terminal B5 (ground) and B6 (power). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions Washer Fluid Level Switch: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8846 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8847 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8848 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8849 Washer Fluid Level Switch: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8850 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8851 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair Windshield Washer Switch: Service and Repair The multi-function switch includes the turn signal, headlight beam select and windshield wiper switches. If any of these switches are found defective, the entire multi-function switch must be replaced. 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever. 3. On all models, remove upper and lower steering column covers, then remove multi-function switch tamper proof mounting screws. 4. Pull switch from column and loosen connector screw, then remove connector from switch. Screw remains in connector. 5. Remove switch from the vehicle. 6. Reverse procedure to install. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment Technical Service Bulletin # 818 Date: 990701 Recall - Inadvertent Airbag Deployment July 1999 Dealer Service Instructions for: Safety Recall No. 818 Airbag System Wiring Models 1994 - 1995 (AS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth Voyager/Grand Voyager IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service as determined by using the DIAL VIP System. Subject The wiring that initiates the driver and/or passenger airbags on about 935,000 of the above vehicles may electrically short circuit to ground. A short circuit to ground that exists immediately after turning the ignition key to the "ON" or "START" position can cause the airbag(s) to inadvertently deply. Inadvertent airbag deployment can injure a front seat occupant. Repair A mastic patch must be installed on every vehicle. In addition, a diagnostic test of the airbag system must be performed. Shorted initiator (squib) wiring must be repaired (which may involve replacing the clockspring). If the rear wiper motor must be replace. Alternate Transportation If inspection determines that clockspring and/or rear wiper motor replacement is required and the vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8879 Use one of the table labor operation numbers and time allowances shown. Add the cost of the parts used plus applicable dealer allowance to your claim. Use the labor operation number and time allowance shown if an owner requires replacement of a rear wiper motor at some time in the future after the recall has already been completed. Parts Return If a REMANUFACTURED rear wiper motor was ordered: Removed rear wiper motors must be returned for core credit as quickly as possible using the Mopar Core Return Procedure on your DIAL terminal. You can access the procedure from Option 4 on the Parts System menu, then select Function 10. If a NEW rear wiper motor was ordered: Removed rear wiper motors must be returned to the Warranty Material Return Center. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing and material return instructions. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8880 DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD818". Owner Notification and Service Scheduling Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8881 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8882 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Provided with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Parts Information A. Mastic Patch Part Number Description 55275444AB Mastic Patch Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Mastic Patches to service about 25% of those vehicles. B. Clockspring Assembly Package Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8883 Part Number Description CCXR8181 Clockspring with Speed Control CCLR8182 Clockspring without Speed Control Each package contains a clockspring and a mastic patch. Due to the small number of involved vehicles expected to require clockspring replacement, each dealer will receive one clockspring for vehicles equipped with speed control. No clockspring assemblies for vehicles without speed control will be distributed initially. Additional clockspring packages should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require clockspring replacement. C. Tie Strap/Clips and Heat Shrink Tubing In addition, each dealer will receive one package often (10) tie strap/clips (P/N 05016944AA) and ten (10) pieces of heat shrink tubing (P/N 04778570) to repair damaged wiring if necessary. Additional tie strap/clips and heat shrink tubing may be ordered as necessary. D. Rear Wiper Motor Assembly Part Number Description R4673326 Remanufactured Rear Wiper Motor Assembly OR 04673326 New Rear Wiper Motor Assembly Due to the small number of involved vehicles expected to require rear wiper motor replacement, no wiper motors will be distributed initially. Wiper motors should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require rear wiper motor replacement. A. Install Mastic Patch & Check For Airbag System Diagnostic Trouble Codes (DTC's): 1. Turn on the rear wiper motor and allow it to run for several cycles, then turn it off. 2. Remove the five (5) steering column cover attaching screws and lower the cover (Figure 1). 3. Disconnect the liftgate release switch electrical connector (Figure 1). 4. Disconnect the parking hand brake linkage. 5. Set the lower steering column cover aside. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8884 6. Install the provided mastic patch on the right edge of the fuse/relay/kneeblocker bracket (Figure 2). 7. Insert the Super Card 2 into the DRB III(R) (Scan Tool) and then using cable CH7020, connect the DRB III to the underdash diagnostic connector (blue connector to the right of the steering column) and power it up. 8. Use the arrow keys and select # 1 - DRB III STAND ALONE on the DRB III MAIN MENU Screen. 9. Turn the ignition key tot he "ON" position. 10. Use the arrow keys and select # 1 - 1983-1997 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU Screen. 11. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the SUPERCARD MAIN MENU Screen. 12. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU Screen. 13. Use the arrow keys and select # 6 - PASSIVE RESTRAINTS on the SELECT SYSTEM Screen. 14. Use the arrow keys and select # 1 - AIRBAG on the SELECT RESTRAINT SYSTEM Screen. 15. Use the arrow keys and select # 2 - READ DTC'S on the SELECT FUNCTION Screen. 16. Use the arrow keys and select # 1 - ACTIVE on the DTC TYPE Screen. 17. Record all active DTC's for future reference. 18. Press the PAGE BACK key to return to the DTC TYPE Screen. 19. Use the arrow keys and select # 2- STORED on the DTC TYPE Screen. 20. Record all stored DTC's for future reference. 21. Press the PAGE BACK key to continue. 22. Use the arrow keys and select ERASE DTC'S on the DTC Screen (if DTC'S were present). 23. Press the PAGE BACK key to continue. 24. Turn the ignition key off and disconnect the DRB III. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8885 25. If the airbag system has one or more of the three DTC's in the table, proceed as shown in the table. If no airbag system DTC's exist, continue with Step 26. NOTE: Refer to the appropriate Diagnostic Manual for the proper diagnostic and repair procedures on any airbag system diagnostic trouble codes other than those listed above. 26. Install the lower steering column cover (Figure 1). 27. Connect the parking hand brake linkage. 28. Connect the liftgate release switch electrical connector (Figure 1). 29. Tighten the lower steering column cover screws securely. 30. Return the vehicle to the customer. No further action is necessary. B. Replace Rear Wiper Motor IMPORTANT: This section is only for vehicles with a "Loss of Ignition Run Only" diagnostic trouble code. 1. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the liftgate wiper arm assembly. 3. Open and raise the liftgate. 4. Remove the two (2) speaker grille/courtesy lamp assemblies (Figure 3). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8886 5. Remove the plugs at the ends of the assist handle and remove the handle attaching screws (Figure 3). 6. Remove the two (2) plugs at the lower corners of the trim panel and remove the lower trim panel screws (Figure 3). 7. Remove the two (2) trim panel screws located in the speaker grille openings (Figure 3). 8. Remove the two (2) plugs near the speaker grille openings in the center of the trim panel and remove the screws (Figure 3). 9. Remove the six (6) trim panel screws along the top edge and upper sides of the trim panel (Figure 3). 10. Disengage the frog leg clips around the perimeter of the trim panel and remove the trim panel from the liftgate. 11. Disconnect the wiper motor electrical connector (Figure 4). 12. Remove the five (5) wiper motor bracket mounting screws (Figure 4). Remove the wiper motor and bracket assembly from the liftgate and set it aside. 13. Install the remanufactured or new rear wiper motor and bracket assembly into the liftgate. Torque the five (5) attaching screws to 35 in-lbs (4 Nm). 14. Connect the wiper motor electrical connector. 15. Position the liftgate trim panel on the liftgate and engage the frog-leg clips around the perimeter of the panel. 16. Install the six (6) screws along the top and upper sides of the trim panel (Figure 3). CAUTION: DO NOT over tighten screws as this could damage the trim panel or strip the screws. 17. Install the two (2) screws located in the speaker grille openings (Figure 3). 18. Install the two (2) screws and plugs in the center of the trim panel (Figure 3). 19. Install the two (2) screws and plugs in the lower trim panel comers (Figure 3). 20. Install the assist handle with the two (2) screws (Figure 3). Install the handle screw plugs. 21. Connect the courtesy lamp electrical connectors and install the speaker grille/courtesy lamp assemblies. 22. Close the liftgate. 23. Install the liftgate wiper arm assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8887 24. In the fuse block located under the instrument panel, replace the rear wiper motor/airbag fuse (Fuse # 13) with a new 20 amp fuse (Figure 5). 25. ^ If any other airbag system diagnostic trouble codes were detected and must be still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 26. 26. Install the lower steering column cover (Figure 1). 27. Connect the parking hand brake linkage. 28. Connect the liftgate release switch electrical connector (Figure 1). 29. Tighten the lower steering column cover screws securely. 30. Turn the ignition switch to the ON position and exit the vehicle. 31. Connect the negative battery terminal. 32. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 33. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. C. Repair Driver Airbag Wiring and.or Replace Clockspring IMPORTANT: This section is only for vehicles with a "Driver Squib Term Shorted to Ground" diagnostic trouble code. 1. Place the steering wheel in the straight ahead position. 2. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 3. Remove the upper and lower steering column shrouds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8888 4. Inspect the clockspring wiring pigtail routed along the steering column for cuts or chafing (Figure 6). ^ If NO cuts or chafing of the clockspring pigtail is found, continue with Step 5. ^ If cuts or chafing of the clockspring pigtail is found, but no wire strands have been damaged, repair the clockspring wires by taping the damaged area with high quality electrical tape and tie strap as shown in Figure 6. ^ If cuts or chafing of the clockspring pigtail is found and internal wire strands have been damaged, replace the clockspring assembly as follows: a. Remove the four (4) airbag module retaining nuts from the back side of the steering wheel, disconnect the airbag module electrical connector and then remove the airbag module from the steering wheel and set it aside (inflator side down/face up for safety). b. Disconnect the speed control switch connector (if equipped). c. Disconnect the horn connector. d. Remove the steering wheel retaining nut and then using a steering wheel puller (Special Tool C-3428B), remove the steering wheel. e. Disconnect the clockspring wiring connector near the top of the fuse block and unclip the wiring pigtail from the steering column. f. Disconnect the clockspring wiring connector from the back of the clockspring. g. Unclip the clockspring assembly locating fingers from the steering column and then remove and discard the clockspring. h. Snap the new clockspring onto the steering column. i. Route the clockspring pigtail down the steering column such that the section of the I/P wiring harness that connects to the ignition switch is between the pigtail and the steering column. Secure the clockspring pigtail to the I/P wiring harness with a tie strap (P/N 05016944AA) (Figure 6). j. Connect the clockspring pigtail to the I/P wiring harness connector. Secure the clockspring pigtail to the I/P wiring harness near the fuse/relay/kneeblocker bracket with a tie strap (P/N 05016944AA) (Figure 6). k. Install the steering wheel. Torque the steering wheel retaining nut to 45 ft-lbs (61 Nm). l. Connect the horn connector. m. Connect the speed control switch connector (if equipped). n. Connect the airbag module electrical connector and install the airbag module onto the steering wheel. Torque the airbag module retaining nuts to 90 in-lbs (10 Nm). 5. Install the upper and lower steering column shrouds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8889 6. Inspect the I/P wiring harness where it is routed past the brake pedal support to verify that the harness tie strap/clip is secured into the hole (Figure 7). ^ If the tie strap/clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 05016944AA) and insert the clip into the hole. 7. Install another mastic patch on the edge of the brake pedal support bracket to prevent damage to the I/P wiring harness as it routes up past the fuse block (Figure 7). 8. Remove the relay access cover. 9. Inspect the I/P wiring harness and verify that the harness tie strap/clip has been inserted into the tab off of the fuse/relay/kneeblocker bracket (Figure 8). ^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 0516944AA) and insert the clip into the hole. 10. Install another mastic patch to the outboard end of the steel tube that routes the transmission shifter cable and the steering column support bracket closest to the I/P wiring harness (Figure 8). 11. Install the relay access cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8890 12. Install the lower steering column cover (Figure 1). 13. Connect the liftgate release switch electrical connector (Figure 1). 14. Connect the liftgate release switch electrical connector (Figure 1). 15. Tighten the lower instruments panel cover screws securely. 16. Remove the two (2) screws that attach the lower console to the instrument panel support brackets (Figure 9). 17. Slide the cupholder out. 18. Remove the two (2) upper console attaching screws behind the cupholder (Figure 9). 19. Slide the console rearward and up to remove. 20. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM) (Figure 10). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8891 21. Install another mastic patch over the rear corner and left edge of the Body Control Module (BCM) (Figure 10). 22. Install the console assembly. 23. Install the upper console attaching screws behind the cupholder. Tighten the screws securely. Close the cupholder. 24. Install the two (2) lower console attaching screws (Figure 9). Tighten the screws securely. 25. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 26. 26. Turn the ignition switch to the ON position and exit the vehicle. 27. Connect the negative battery terminal. 28. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 29. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. D. Repair Passenger Airbag Wiring IMPORTANT: This section is only for vehicles with a "Passenger Squib Term Shorted to Ground" diagnostic trouble code. 1. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the two (2) screws that attach the lower console to the instrument panel support brackets (Figure 11). 3. Slide the cupholder out. 4. Remove the two (2) upper console attaching screws behind the cupholder (Figure 11). 5. Slide the console rearward and up to remove. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8892 6. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM) (Figure 12). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. 7. Install a mastic patch over the rear corner and left edge of the Body Control Module (BCM) (Figure 12). 8. Inspect the I/P wiring harness above the AECM and the BCM. Verify that the clip on the harness is installed into the hole on the back side of the left center console bracket (Figure 12). ^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the clip is missing or is damaged, install a new tie strap/clip (P/N 05016944AA) and insert the clip into the hole. 9. Install the console assembly. 10. Install the upper console attaching screws behind the cupholder. Tighten the screws securely (Figure 11). Close the cupholder. 11. Install the two (2) lower console attaching screws (Figure 11). Tighten the screws securely. 12. Disconnect the glove box door check straps and allow the door to open fully. 13. Working through the glove box opening, remove the four (4) screws that attach the passenger airbag module to the I/P bracket (Figure 13). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8893 14. Using a large flat-tipped screwdriver, pry the module up to unsnap the door from the trim pad and lift it away from the snaps (Figure 14). 15. Hold the passenger airbag module door and raise the module from the opening. DO NOT disconnect the airbag module electrical connectors. 16. Inspect the I/P wiring harness just behind the passenger airbag connectors (Figure 15). Any chafed or cut wires should be repaired per the Wiring Repair. 17. Install a mastic patch on the edge of the passenger airbag module near the electrical connectors (Figure 15). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8894 18. Inspect the passenger airbag module takeout on the I/P wiring harness near the vertical support bracket attached to the lip support tube (Figure 16). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. 19. Install a mastic patch on the bottom edge of the support bracket just below the existing plastic edge cover (Figure 16). 20. Install the passenger airbag module into the I/P. Tighten the module attaching screws to 50 in-lbs (6 Nm) 21. Connect the glove box door check straps and then close the glove box door. 22. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 23. 23. Install the lower steering column cover (Figure 1). 24. Connect the parking hand brake linkage (Figure 1). 25. Connect the liftgate release switch electrical connector (Figure 1). 26. Tighten the lower steering column cover screws securely. 27. Turn the ignition switch to the ON position and exit the vehicle. 28. Connect the negative battery terminal. 29. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 30. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Wiring Repair Procedure IMPORTANT: If airbag system wiring is found chafed or damaged, the wiring should be repaired using the procedure listed below. ^ If the plastic wire covering is chafed but the wiring strands are NOT damaged: Tape the damaged area with high quality electrical tape. ^ If the plastic wire covering is chafed and the wiring strands are damaged: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8895 1. Cut the damaged wire in two. 2. Strip 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing, P/N 04778570, on one end of the wire. 4. Spread the strands of the wire apart on both of the exposed wire ends. 5. Push the two wire ends together until the strands of the wire are close to the insulation. 6. Twist the wires together. 7. Solder the connection together using rosin core solder. 8. Center the heat shrink tubing over the repair area and apply heat with a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out both ends of the tubing. 9. Secure the wire to the harness to prevent chafing or damage to the insulation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment Technical Service Bulletin # 818 Date: 990701 Recall - Inadvertent Airbag Deployment July 1999 Dealer Service Instructions for: Safety Recall No. 818 Airbag System Wiring Models 1994 - 1995 (AS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth Voyager/Grand Voyager IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service as determined by using the DIAL VIP System. Subject The wiring that initiates the driver and/or passenger airbags on about 935,000 of the above vehicles may electrically short circuit to ground. A short circuit to ground that exists immediately after turning the ignition key to the "ON" or "START" position can cause the airbag(s) to inadvertently deply. Inadvertent airbag deployment can injure a front seat occupant. Repair A mastic patch must be installed on every vehicle. In addition, a diagnostic test of the airbag system must be performed. Shorted initiator (squib) wiring must be repaired (which may involve replacing the clockspring). If the rear wiper motor must be replace. Alternate Transportation If inspection determines that clockspring and/or rear wiper motor replacement is required and the vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8901 Use one of the table labor operation numbers and time allowances shown. Add the cost of the parts used plus applicable dealer allowance to your claim. Use the labor operation number and time allowance shown if an owner requires replacement of a rear wiper motor at some time in the future after the recall has already been completed. Parts Return If a REMANUFACTURED rear wiper motor was ordered: Removed rear wiper motors must be returned for core credit as quickly as possible using the Mopar Core Return Procedure on your DIAL terminal. You can access the procedure from Option 4 on the Parts System menu, then select Function 10. If a NEW rear wiper motor was ordered: Removed rear wiper motors must be returned to the Warranty Material Return Center. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing and material return instructions. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8902 DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD818". Owner Notification and Service Scheduling Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8903 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8904 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is included. Provided with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Parts Information A. Mastic Patch Part Number Description 55275444AB Mastic Patch Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Mastic Patches to service about 25% of those vehicles. B. Clockspring Assembly Package Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8905 Part Number Description CCXR8181 Clockspring with Speed Control CCLR8182 Clockspring without Speed Control Each package contains a clockspring and a mastic patch. Due to the small number of involved vehicles expected to require clockspring replacement, each dealer will receive one clockspring for vehicles equipped with speed control. No clockspring assemblies for vehicles without speed control will be distributed initially. Additional clockspring packages should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require clockspring replacement. C. Tie Strap/Clips and Heat Shrink Tubing In addition, each dealer will receive one package often (10) tie strap/clips (P/N 05016944AA) and ten (10) pieces of heat shrink tubing (P/N 04778570) to repair damaged wiring if necessary. Additional tie strap/clips and heat shrink tubing may be ordered as necessary. D. Rear Wiper Motor Assembly Part Number Description R4673326 Remanufactured Rear Wiper Motor Assembly OR 04673326 New Rear Wiper Motor Assembly Due to the small number of involved vehicles expected to require rear wiper motor replacement, no wiper motors will be distributed initially. Wiper motors should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require rear wiper motor replacement. A. Install Mastic Patch & Check For Airbag System Diagnostic Trouble Codes (DTC's): 1. Turn on the rear wiper motor and allow it to run for several cycles, then turn it off. 2. Remove the five (5) steering column cover attaching screws and lower the cover (Figure 1). 3. Disconnect the liftgate release switch electrical connector (Figure 1). 4. Disconnect the parking hand brake linkage. 5. Set the lower steering column cover aside. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8906 6. Install the provided mastic patch on the right edge of the fuse/relay/kneeblocker bracket (Figure 2). 7. Insert the Super Card 2 into the DRB III(R) (Scan Tool) and then using cable CH7020, connect the DRB III to the underdash diagnostic connector (blue connector to the right of the steering column) and power it up. 8. Use the arrow keys and select # 1 - DRB III STAND ALONE on the DRB III MAIN MENU Screen. 9. Turn the ignition key tot he "ON" position. 10. Use the arrow keys and select # 1 - 1983-1997 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU Screen. 11. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the SUPERCARD MAIN MENU Screen. 12. Use the arrow keys and select # 1 - 1994-1997 DIAGNOSTICS on the DRB III STAND-ALONE MAIN MENU Screen. 13. Use the arrow keys and select # 6 - PASSIVE RESTRAINTS on the SELECT SYSTEM Screen. 14. Use the arrow keys and select # 1 - AIRBAG on the SELECT RESTRAINT SYSTEM Screen. 15. Use the arrow keys and select # 2 - READ DTC'S on the SELECT FUNCTION Screen. 16. Use the arrow keys and select # 1 - ACTIVE on the DTC TYPE Screen. 17. Record all active DTC's for future reference. 18. Press the PAGE BACK key to return to the DTC TYPE Screen. 19. Use the arrow keys and select # 2- STORED on the DTC TYPE Screen. 20. Record all stored DTC's for future reference. 21. Press the PAGE BACK key to continue. 22. Use the arrow keys and select ERASE DTC'S on the DTC Screen (if DTC'S were present). 23. Press the PAGE BACK key to continue. 24. Turn the ignition key off and disconnect the DRB III. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8907 25. If the airbag system has one or more of the three DTC's in the table, proceed as shown in the table. If no airbag system DTC's exist, continue with Step 26. NOTE: Refer to the appropriate Diagnostic Manual for the proper diagnostic and repair procedures on any airbag system diagnostic trouble codes other than those listed above. 26. Install the lower steering column cover (Figure 1). 27. Connect the parking hand brake linkage. 28. Connect the liftgate release switch electrical connector (Figure 1). 29. Tighten the lower steering column cover screws securely. 30. Return the vehicle to the customer. No further action is necessary. B. Replace Rear Wiper Motor IMPORTANT: This section is only for vehicles with a "Loss of Ignition Run Only" diagnostic trouble code. 1. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the liftgate wiper arm assembly. 3. Open and raise the liftgate. 4. Remove the two (2) speaker grille/courtesy lamp assemblies (Figure 3). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8908 5. Remove the plugs at the ends of the assist handle and remove the handle attaching screws (Figure 3). 6. Remove the two (2) plugs at the lower corners of the trim panel and remove the lower trim panel screws (Figure 3). 7. Remove the two (2) trim panel screws located in the speaker grille openings (Figure 3). 8. Remove the two (2) plugs near the speaker grille openings in the center of the trim panel and remove the screws (Figure 3). 9. Remove the six (6) trim panel screws along the top edge and upper sides of the trim panel (Figure 3). 10. Disengage the frog leg clips around the perimeter of the trim panel and remove the trim panel from the liftgate. 11. Disconnect the wiper motor electrical connector (Figure 4). 12. Remove the five (5) wiper motor bracket mounting screws (Figure 4). Remove the wiper motor and bracket assembly from the liftgate and set it aside. 13. Install the remanufactured or new rear wiper motor and bracket assembly into the liftgate. Torque the five (5) attaching screws to 35 in-lbs (4 Nm). 14. Connect the wiper motor electrical connector. 15. Position the liftgate trim panel on the liftgate and engage the frog-leg clips around the perimeter of the panel. 16. Install the six (6) screws along the top and upper sides of the trim panel (Figure 3). CAUTION: DO NOT over tighten screws as this could damage the trim panel or strip the screws. 17. Install the two (2) screws located in the speaker grille openings (Figure 3). 18. Install the two (2) screws and plugs in the center of the trim panel (Figure 3). 19. Install the two (2) screws and plugs in the lower trim panel comers (Figure 3). 20. Install the assist handle with the two (2) screws (Figure 3). Install the handle screw plugs. 21. Connect the courtesy lamp electrical connectors and install the speaker grille/courtesy lamp assemblies. 22. Close the liftgate. 23. Install the liftgate wiper arm assembly. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8909 24. In the fuse block located under the instrument panel, replace the rear wiper motor/airbag fuse (Fuse # 13) with a new 20 amp fuse (Figure 5). 25. ^ If any other airbag system diagnostic trouble codes were detected and must be still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 26. 26. Install the lower steering column cover (Figure 1). 27. Connect the parking hand brake linkage. 28. Connect the liftgate release switch electrical connector (Figure 1). 29. Tighten the lower steering column cover screws securely. 30. Turn the ignition switch to the ON position and exit the vehicle. 31. Connect the negative battery terminal. 32. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 33. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. C. Repair Driver Airbag Wiring and.or Replace Clockspring IMPORTANT: This section is only for vehicles with a "Driver Squib Term Shorted to Ground" diagnostic trouble code. 1. Place the steering wheel in the straight ahead position. 2. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 3. Remove the upper and lower steering column shrouds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8910 4. Inspect the clockspring wiring pigtail routed along the steering column for cuts or chafing (Figure 6). ^ If NO cuts or chafing of the clockspring pigtail is found, continue with Step 5. ^ If cuts or chafing of the clockspring pigtail is found, but no wire strands have been damaged, repair the clockspring wires by taping the damaged area with high quality electrical tape and tie strap as shown in Figure 6. ^ If cuts or chafing of the clockspring pigtail is found and internal wire strands have been damaged, replace the clockspring assembly as follows: a. Remove the four (4) airbag module retaining nuts from the back side of the steering wheel, disconnect the airbag module electrical connector and then remove the airbag module from the steering wheel and set it aside (inflator side down/face up for safety). b. Disconnect the speed control switch connector (if equipped). c. Disconnect the horn connector. d. Remove the steering wheel retaining nut and then using a steering wheel puller (Special Tool C-3428B), remove the steering wheel. e. Disconnect the clockspring wiring connector near the top of the fuse block and unclip the wiring pigtail from the steering column. f. Disconnect the clockspring wiring connector from the back of the clockspring. g. Unclip the clockspring assembly locating fingers from the steering column and then remove and discard the clockspring. h. Snap the new clockspring onto the steering column. i. Route the clockspring pigtail down the steering column such that the section of the I/P wiring harness that connects to the ignition switch is between the pigtail and the steering column. Secure the clockspring pigtail to the I/P wiring harness with a tie strap (P/N 05016944AA) (Figure 6). j. Connect the clockspring pigtail to the I/P wiring harness connector. Secure the clockspring pigtail to the I/P wiring harness near the fuse/relay/kneeblocker bracket with a tie strap (P/N 05016944AA) (Figure 6). k. Install the steering wheel. Torque the steering wheel retaining nut to 45 ft-lbs (61 Nm). l. Connect the horn connector. m. Connect the speed control switch connector (if equipped). n. Connect the airbag module electrical connector and install the airbag module onto the steering wheel. Torque the airbag module retaining nuts to 90 in-lbs (10 Nm). 5. Install the upper and lower steering column shrouds. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8911 6. Inspect the I/P wiring harness where it is routed past the brake pedal support to verify that the harness tie strap/clip is secured into the hole (Figure 7). ^ If the tie strap/clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 05016944AA) and insert the clip into the hole. 7. Install another mastic patch on the edge of the brake pedal support bracket to prevent damage to the I/P wiring harness as it routes up past the fuse block (Figure 7). 8. Remove the relay access cover. 9. Inspect the I/P wiring harness and verify that the harness tie strap/clip has been inserted into the tab off of the fuse/relay/kneeblocker bracket (Figure 8). ^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the tie strap/clip is missing or damaged, install a new tie strap/clip (P/N 0516944AA) and insert the clip into the hole. 10. Install another mastic patch to the outboard end of the steel tube that routes the transmission shifter cable and the steering column support bracket closest to the I/P wiring harness (Figure 8). 11. Install the relay access cover. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8912 12. Install the lower steering column cover (Figure 1). 13. Connect the liftgate release switch electrical connector (Figure 1). 14. Connect the liftgate release switch electrical connector (Figure 1). 15. Tighten the lower instruments panel cover screws securely. 16. Remove the two (2) screws that attach the lower console to the instrument panel support brackets (Figure 9). 17. Slide the cupholder out. 18. Remove the two (2) upper console attaching screws behind the cupholder (Figure 9). 19. Slide the console rearward and up to remove. 20. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM) (Figure 10). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8913 21. Install another mastic patch over the rear corner and left edge of the Body Control Module (BCM) (Figure 10). 22. Install the console assembly. 23. Install the upper console attaching screws behind the cupholder. Tighten the screws securely. Close the cupholder. 24. Install the two (2) lower console attaching screws (Figure 9). Tighten the screws securely. 25. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 26. 26. Turn the ignition switch to the ON position and exit the vehicle. 27. Connect the negative battery terminal. 28. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 29. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. D. Repair Passenger Airbag Wiring IMPORTANT: This section is only for vehicles with a "Passenger Squib Term Shorted to Ground" diagnostic trouble code. 1. With the ignition switch in the OFF position, disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the two (2) screws that attach the lower console to the instrument panel support brackets (Figure 11). 3. Slide the cupholder out. 4. Remove the two (2) upper console attaching screws behind the cupholder (Figure 11). 5. Slide the console rearward and up to remove. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8914 6. Inspect the I/P wiring harness where it connects to the Airbag Electronic Control Module (AECM) (Figure 12). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. 7. Install a mastic patch over the rear corner and left edge of the Body Control Module (BCM) (Figure 12). 8. Inspect the I/P wiring harness above the AECM and the BCM. Verify that the clip on the harness is installed into the hole on the back side of the left center console bracket (Figure 12). ^ If the clip is on the harness but not in the hole, inspect the wiring harness for damage. Any chafed or cut wires should be repaired per the Wiring Repair Procedure. ^ If the clip is missing or is damaged, install a new tie strap/clip (P/N 05016944AA) and insert the clip into the hole. 9. Install the console assembly. 10. Install the upper console attaching screws behind the cupholder. Tighten the screws securely (Figure 11). Close the cupholder. 11. Install the two (2) lower console attaching screws (Figure 11). Tighten the screws securely. 12. Disconnect the glove box door check straps and allow the door to open fully. 13. Working through the glove box opening, remove the four (4) screws that attach the passenger airbag module to the I/P bracket (Figure 13). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8915 14. Using a large flat-tipped screwdriver, pry the module up to unsnap the door from the trim pad and lift it away from the snaps (Figure 14). 15. Hold the passenger airbag module door and raise the module from the opening. DO NOT disconnect the airbag module electrical connectors. 16. Inspect the I/P wiring harness just behind the passenger airbag connectors (Figure 15). Any chafed or cut wires should be repaired per the Wiring Repair. 17. Install a mastic patch on the edge of the passenger airbag module near the electrical connectors (Figure 15). Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8916 18. Inspect the passenger airbag module takeout on the I/P wiring harness near the vertical support bracket attached to the lip support tube (Figure 16). Any chafed or cut wires should be repaired per the Wiring Repair Procedure. 19. Install a mastic patch on the bottom edge of the support bracket just below the existing plastic edge cover (Figure 16). 20. Install the passenger airbag module into the I/P. Tighten the module attaching screws to 50 in-lbs (6 Nm) 21. Connect the glove box door check straps and then close the glove box door. 22. ^ If any other airbag system diagnostic trouble codes were detected and must still be repaired, continue with the appropriate section of the Service Procedure to correct that issue. ^ If no other diagnostic trouble codes require correction, continue with Step 23. 23. Install the lower steering column cover (Figure 1). 24. Connect the parking hand brake linkage (Figure 1). 25. Connect the liftgate release switch electrical connector (Figure 1). 26. Tighten the lower steering column cover screws securely. 27. Turn the ignition switch to the ON position and exit the vehicle. 28. Connect the negative battery terminal. 29. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then back to the ON position. 30. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Wiring Repair Procedure IMPORTANT: If airbag system wiring is found chafed or damaged, the wiring should be repaired using the procedure listed below. ^ If the plastic wire covering is chafed but the wiring strands are NOT damaged: Tape the damaged area with high quality electrical tape. ^ If the plastic wire covering is chafed and the wiring strands are damaged: Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 818 > Jul > 99 > Recall - Inadvertent Airbag Deployment > Page 8917 1. Cut the damaged wire in two. 2. Strip 1 inch of insulation from each end of the wire. 3. Place a piece of heat shrink tubing, P/N 04778570, on one end of the wire. 4. Spread the strands of the wire apart on both of the exposed wire ends. 5. Push the two wire ends together until the strands of the wire are close to the insulation. 6. Twist the wires together. 7. Solder the connection together using rosin core solder. 8. Center the heat shrink tubing over the repair area and apply heat with a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out both ends of the tubing. 9. Secure the wire to the harness to prevent chafing or damage to the insulation. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 08-07-98 > Mar > 98 > Airbag - Warning Light Illumination Wiper Motor: All Technical Service Bulletins Airbag - Warning Light Illumination NO: 08-07-98 GROUP: Electrical DATE: Mar. 6, 1998 SUBJECT: Airbag Warning Light illumination Caused By A Short in The Rear Wiper Motor/Circuit MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) DISCUSSION: Some subject vehicles may experience a short in the rear wiper motor/circuit causing fuse # 13 to blow which illuminates the Airbag Warning light in the instrument panel. When a short in the rear wiper motor/circuit causes fuse # 13 to blow, the Airbag Warning light is "ON" but the airbag system still receives power through fuse # 20 and is fully functional, providing the same occupant protection as when the light is not illuminated. However, when this condition occurs, it hides a proper warning if an airbag system fault were to occur. Due to the age of the involved vehicles, some owners may prefer to minimize their expense to turn off the Airbag Warning light. For owners seeking a less expensive alternative, if the rear wiper motor itself is the source of the short, the wiper motor wiring connector can be disconnected and isolated. Then, when fuse # 13 is replaced, the Airbag Warning light will be extinguished, allowing the Airbag Warning light to indicate real airbag system faults if they should occur. Use a DRB III to check for any stored airbag Diagnostic Trouble Codes (DTC's). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiper Motor: > 085394 > Oct > 94 > Engine Starter - Intermittent No Crank Wiper Motor: All Technical Service Bulletins Airbag - Warning Light Illumination NO: 08-07-98 GROUP: Electrical DATE: Mar. 6, 1998 SUBJECT: Airbag Warning Light illumination Caused By A Short in The Rear Wiper Motor/Circuit MODELS: 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1995 (ES) Chrysler Voyager (European Market) DISCUSSION: Some subject vehicles may experience a short in the rear wiper motor/circuit causing fuse # 13 to blow which illuminates the Airbag Warning light in the instrument panel. When a short in the rear wiper motor/circuit causes fuse # 13 to blow, the Airbag Warning light is "ON" but the airbag system still receives power through fuse # 20 and is fully functional, providing the same occupant protection as when the light is not illuminated. However, when this condition occurs, it hides a proper warning if an airbag system fault were to occur. Due to the age of the involved vehicles, some owners may prefer to minimize their expense to turn off the Airbag Warning light. For owners seeking a less expensive alternative, if the rear wiper motor itself is the source of the short, the wiper motor wiring connector can be disconnected and isolated. Then, when fuse # 13 is replaced, the Airbag Warning light will be extinguished, allowing the Airbag Warning light to indicate real airbag system faults if they should occur. Use a DRB III to check for any stored airbag Diagnostic Trouble Codes (DTC's). POLICY: Information Only Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Page 8927 Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Page 8928 Wiper Motor: Testing and Inspection Fig 9 Liftgate Wiper Motor Electrical Connector 1. Disconnect electrical connector at wiper motor. 2. Place ignition switch in On position, then check for battery voltage at blue wire. 3. Place wiper switch in On position and check battery voltage between blue and brown wires. 4. If battery voltage was not present in preceding steps, proceed as follows: a. Check fuse, liftgate wiper switch and wiring. b. With ignition switch in On position and wiper switch in Off position, check for battery voltage between blue and brown wires. If battery voltage is not present, check ground wire to liftgate switch. 5. If battery voltage was present in preceding steps, replace motor. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Rear Wiper Motor Replacement Wiper Motor: Service and Repair Rear Wiper Motor Replacement 1. Remove wiper arm, open liftgate and remove trim panel. 2. Remove wiper motor mounting screws and disconnect electrical connector. 3. Remove motor from liftgate. 4. Reverse procedure to install. Torque mounting screws to 25-45 inch lbs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Rear Wiper Motor Replacement > Page 8931 Wiper Motor: Service and Repair Replacement 1. Disconnect battery ground cable, then remove wiper arms. 2. Open hood and remove cowl top plenum grille, then disconnect wiper fluid hoses. 3. Remove cowl plenum chamber plastic screen, then the wiper pivot screws. 4. Push pivots down into plenum chamber, then remove nut from wiper output shaft and linkage assembly. 5. Disconnect wiper motor electrical connector, then remove wiper motor mounting screw and nuts. 6. Remove wiper motor. 7. Reverse procedure to install, noting the following: a. Torque pivot screws, mounting screws and nuts to 5-6 ft. lbs. b. Torque drive crank shaft nut to 7.5-8.5 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Wiper Switch: Diagrams Multi-Function Switch Connector Dodge Grand Caravan Workshop Manual (V6-201 3.3L (1994)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 8935 Rear Wiper Switch Connector