1996 CHRYSLER VOYAGER Service Manual

(9) Verify liftgate alignment. The liftgate should
have a gap to adjacent panels and fit flush across the
gaps. The gap is;
²7 mm (0.280 in.) to the fascia,
²6 mm (0.240 in.) to the roof,
²4 mm (0.160 in.) to the aperture.
LIFTGATE CHMSL ACCESS PANEL
REMOVAL
(1) Using a trim stick (C-4755), disengage clips
holding CHMSL access panel to liftgate trim panel.
(2) Remove access panel from vehicle.
INSTALLATION
(1) Place access panel in position on vehicle.
(2) Engage clips to hold CHMSL access panel to
liftgate trim panel.
LIFTGATE HINGE
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Support liftgate on a suitable lifting device.
(3) Apply several layers of duct tape on the outside
of to roof across the gap to the lift gate to hold the
liftgate in position.
(4) Remove bolts holding liftgate hinge to roof
header.
(5) Remove bolts holding hinge to liftgate (Fig. 56).
(6) Remove hinge from vehicle.
INSTALLATION
(1) If necessary, paint replacement hinge before
installation.
(2) Place hinge in position on vehicle.
(3) Align hinge to marks on liftgate.
(4) Install bolts to hold hinge to liftgate (Fig. 56).
(5) Align hinge to marks on roof header.(6) Install bolts to hold liftgate hinge to roof
header.
(7) Remove duct tape from roof and liftgate.
(8) Support liftgate on a suitable lifting device.
(9) Verify liftgate alignment. Refer to Liftgate
Remove and Installation for proper gap measure-
ments.
LIFTGATE LATCH
REMOVAL
(1) Remove liftgate trim panel.
(2) Disengage outside handle link from clip on
latch.
(3) Disconnect wire connector from liftgate ajar
switch (Fig. 57).
(4) Remove screws holding latch to liftgate.
(5) Remove latch from vehicle.
INSTALLATION
(1) Place latch in position on vehicle.
(2) Install screws to hold latch to liftgate.
(3) Pull downward on outside handle link and
engage link to clip on latch.
(4) Connect wire connector to liftgate ajar switch.
(5) Verify liftgate fit and operation. Adjust as nec-
essary.
(6) Install liftgate trim panel.
LIFTGATE LATCH STRIKER
REMOVAL
(1) Open liftgate.
(2) Mark outline of striker on sill to aid installa-
tion.
(3) Remove screws attaching striker to sill (Fig.
58).
(4) Remove striker from vehicle.
Fig. 56 Liftgate Hinge
Fig. 57 Liftgate Latch
NSBODY 23 - 47
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Place striker in position on vehicle.
(2) Align striker to outline mark on sill.
(3) Install screws to attach striker to sill.
(4) Verify liftgate alignment and operation.
LIFTGATE LOCK CYLINDER
REMOVAL
NOTE: Do not remove E-clip.
(1) Remove outside liftgate handle.
(2) Remove lock cylinder clip from handle (Fig. 59).
(3) Remove lock cylinder and arm from handle.
INSTALLATION
(1) Install lock cylinder clip into liftgate handle.
(2) Push lock cylinder into handle until clip
engages groove in lock cylinder with an audible click
(Fig. 60).
(3) Install outside liftgate handle.
(4) Verify lock cylinder operation.
LIFTGATE OUTSIDE HANDLE
REMOVAL
(1) Remove liftgate trim panel.
(2) Remove power lock motor.
(3) Disengage outside handle link from clip on lift-
gate latch.
(4) Disconnect VTSS switch from back of lock cyl-
inder, if equipped.
(5) Disengage lock link, if equipped.
(6) Remove nut attaching outside liftgate handle to
liftgate (Fig. 61).
(7) Disengage retaining groove holding handle to
liftgate.
(8) Remove outside liftgate handle and links from
vehicle.
INSTALLATION
(1) Position outside liftgate handle and links on
vehicle.
(2) Engage retaining groove to hold handle to lift-
gate by pushing handle to the right for centering.
(3) Install nut to attach outside liftgate handle to
liftgate.
Fig. 58 Liftgate Latch Striker
Fig. 59 Lock Cylinder Removal
Fig. 60 Lock Cylinder Installation
23 - 48 BODYNS
REMOVAL AND INSTALLATION (Continued)

(4) Connect VTSS switch from back of lock cylin-
der, if equipped.
(5) Engage outside handle link to clip on liftgate
latch.
(6) Install lock link, if equipped.
(7) Install power lock motor.
(8) Verify liftgate operation. Adjust as necessary.
(9) Install liftgate trim panel.
LIFTGATE PROP ASSEMBLY
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Support liftgate on a suitable lifting device.
(3) Pull liftgate opening weatherstrip from D-pillar
flange next to prop assembly end pivot.
(4) Remove bolt holding end pivot to D-pillar (Fig.
62).
(5) Remove bolt holding prop assembly to liftgate.
(6) Remove prop assembly from vehicle.
INSTALLATION
For installation, reverse the above procedures.
LIFTGATE SILL PLATE
REMOVAL
(1) Disengage hidden clips holding sill plate to lift-
gate door opening sill (Fig. 63).
(2) Remove sill plate from vehicle.
INSTALLATION
(1) Place sill plate in position on vehicle.
(2) Align locator rib into recess in liftgate sill.
(3) Engage hidden clips to hold sill plate to liftgate
door opening sill.
LIFTGATE STABILIZER WEDGE
REMOVAL
(1) Open liftgate.
(2) Mark outline of stabilizer wedge on liftgate to
aid installation.
(3) Remove rivets attaching wedge to liftgate (Fig.
64).
(4) Remove wedge from vehicle.
INSTALLATION
(1) Position stabilizer wedge on vehicle.
(2) Align stabilizer wedge to outline previously
made on liftgate.
(3) Install rivet to hold wedge to liftgate.
(4) Verify liftgate fit and operation. Adjust as nec-
essary.
LIFTGATE STABILIZER WEDGE STRIKER
REMOVAL
(1) Open liftgate.
Fig. 61 Liftgate Outside HandleFig. 62 Liftgate Prop Assembly
Fig. 63 Liftgate Sill Plate
NSBODY 23 - 49
REMOVAL AND INSTALLATION (Continued)

(2) Remove screws attaching stabilizer wedge
striker to D-pillar (Fig. 65).
(3) Retrieve shims from between wedge striker and
D-pillar, if necessary.
(4) Remove wedge striker from vehicle.
INSTALLATION
(1) Position wedge striker on vehicle.
(2) Install any shims previously retrieved from
between wedge striker and D-pillar or add shims to
ensure proper contact.
(3) Install screws attaching stabilizer wedge
striker to D-pillar (Fig. 65).
LIFTGATE TRIM PANEL
REMOVAL
(1) Remove liftgate upper frame molding.
(2) Remove upper frame side moldings.
(3) Remove screws holding assist handle to liftgate
and fasteners around the perimeter of the lower trim
panel.(4) If equipped, using a trim stick (C-4755), pry
courtesy lamps from liftgate trim.
(5) Disconnect wire connector from lamp.
(6) Remove CHMSL cover and fasteners holding
the trim panel.
(7) Disengage hidden clips holding trim panel to
liftgate from around perimeter or liftgate (Fig. 66).
(8) Remove liftgate trim panel from vehicle.
INSTALLATION
(1) Place liftgate trim panel in position on vehicle.
(2) Engage hidden clips to hold trim panel to lift-
gate and fasteners around perimeter of liftgate (Fig.
66).
(3) Install fasteners into trim brackets and install
CHMSL cover.
(4) Connect wire connector into lamp.
(5) Install courtesy lamps into liftgate trim.
(6) Install screws to hold assist handle to liftgate.
(7) Install upper frame side moldings.
(8) Install liftgate upper frame molding.
LIFTGATE UPPER FRAME MOLDING
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Disengage hidden clips holding molding to lift-
gate upper frame (Fig. 66).
(3) Remove liftgate upper molding from vehicle.
INSTALLATION
(1) Place liftgate upper molding in position on
vehicle.
Fig. 64 Liftgate Wedge
Fig. 65 Liftgate Wedge Striker
Fig. 66 Liftgate Trim
23 - 50 BODYNS
REMOVAL AND INSTALLATION (Continued)