1996 CHRYSLER VOYAGER check oil

²Improper operation
HARD SHIFTING
Hard shifting may be caused by a misadjusted
crossover cable. If hard shifting is accompanied by
gear clash, synchronizer clutch and stop rings or gear
teeth may be worn or damaged.
Misassembled synchronizer components also cause
shifting problems. Incorrectly installed synchronizer
sleeves, struts, or springs can cause shift problems.
NOISY OPERATION
Transaxle noise is most often a result of worn or
damaged components. Chipped, broken gear or syn-
chronizer teeth, and brinnelled, spalled bearings all
cause noise.
Abnormal wear and damage to the internal compo-
nents is frequently the end result of insufficient
lubricant.
SLIPS OUT OF GEAR
Transaxle disengagement may be caused by mis-
aligned or damaged shift components, or worn teeth
on the drive gears or synchronizer components. Incor-
rect assembly also causes gear disengagement.
LOW LUBRICANT LEVEL
Insufficient transaxle lubricant is usually the
result of leaks, or inaccurate fluid level check or refill
method. Leakage is evident by the presence of oil
around the leak point. If leakage is not evident, the
condition is probably the result of an underfill.
If air±powered lubrication equipment is used to fill
a transaxle, be sure the equipment is properly cali-
brated. Equipment out of calibration can lead to an
underfill condition.
The transaxle fill plug is located on the lower left
side of the transaxle end cover. With the vehicle at a
level position, remove the fill plug and check the
level of the lubricant. The lubricant level should be
within 3.175mm (1/8 inch) from the bottom of the fill
hole. If the lubricant level is low, fill the transaxle to
the bottom of the fill hole with SAE 5W-30 engine oil,
meeting SG and/or SG-CD qualifications, as the fac-
tory fill lubricant. SAE GL5 10W-40 engine oil is a
suitable service fill alternative.
CLUTCH PROBLEMS
Worn, damaged, or misaligned clutch components
can cause difficult shifting, gear clash, and noise.
A worn or damaged clutch disc, pressure plate, or
release bearing can cause hard shifting and gear
clash.
SERVICE PROCEDURES
FLUID DRAIN AND FILL
TRANSAXLE FLUID DRAIN
(1) Hoist vehicle.
(2) Install a drain pan underneath the transaxle
drain plug.
(3) Remove the transaxle drain plug. The drain
plug is located on the bottom of the transaxle hous-
ing.
(4) Let fluid drain out till there is just an occa-
sional drip.
(5) Reinstall drain plug. Tighten drain plug to 28
N´m (250 in. lbs.)
TRANSAXLE FLUID FILL
NOTE: All A-598 transaxles are equipped with a fill
plug. The fill plug is located on the end cover side
of the transaxle.
(1) Remove transaxle fill plug
The fluid level should be within 3.175mm (1/8
inch) from the bottom of the transaxle fill hole (vehi-
cle must be level when checking).
(2) Fill transaxle to proper level with SAE 5W-30
engine oil, meeting SG and/or SG-CD qualifications.
G5 SAE 10W-40 engine oil is a suitable service fill
alternative. Dry fill lubricant capacity is approxi-
mately 1.9-2.2 liters (4.0-4.6 pints)..
(3) Wipe the outside of the transaxle if any lubri-
cant spills.
(4) Reinstall transaxle fill plug.
FLUID DRAIN AND FILLÐRHD VEHICLES
TRANSAXLE FLUID DRAIN
(1) Hoist vehicle.
(2) Install a drain pan underneath the transaxle
drain plug.
(3) Remove the transaxle drain plug. The drain
plug is located on the bottom of the transaxle hous-
ing (Fig. 5).
(4) Let fluid drain out till there is just an occa-
sional drip.
(5) Reinstall drain plug. Tighten drain plug to 28
N´m (250 in. lbs.)
TRANSAXLE FLUID FILL
NOTE: All A-558 transaxles are equipped with a fill
plug. The fill plug is located on the end cover side
of the transaxle.
(1) Remove transaxle fill plug
21 - 4 A±598 MANUAL TRANSAXLENS/GS
DIAGNOSIS AND TESTING (Continued)

The fluid level should be within 3.175mm (1/8
inch) from the bottom of the transaxle fill hole (vehi-
cle must be level when checking).
(2) Fill transaxle to proper level with SAE 5W-30
engine oil, meeting SG and/or SG-CD qualifications.
G5 SAE 10W-40 engine oil is a suitable service fill
alternative. Dry fill lubricant capacity is approxi-
mately 1.9-2.2 liters (4.0-4.6 pints).
(3) Wipe the outside of the transaxle if any lubri-
cant spills.
(4) Reinstall transaxle fill plug.
REMOVAL AND INSTALLATION
GEARSHIFT KNOB
REMOVAL
(1) Pull shifter boot down and away from shifter
roll pin.
(2) Pry legs of shift knob away from shift lever roll
pin using a flat blade pry tool (Fig. 6).(3) Remove knob from shifter handle.
INSTALLATION
(1) For installation, reverse removal procedure,
omitting step (2).
GEARSHIFT BOOT
REMOVAL
(1) Remove shifter knob. Refer to gearshift knob
removal.
(2) Pull up on boot until retention clips disengage
from the console and remove (Fig. 7).
INSTALLATION
(1) For installation, reverse removal procedure,
taking care to fully engage the retention clips.
GEARSHIFT BOOT
REMOVAL
(1) Remove shifter knob. Refer to gearshift knob
removal.
(2) Pull up on boot until retention clips disengage
from the console and remove (Fig. 8).
INSTALLATION
(1) For installation, reverse removal procedure,
taking care to fully engage the retention clips.
GEARSHIFT CABLES
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove air cleaner assembly.
(3) Disconnect gearshift cable ends from transaxle
shift levers (Fig. 9) (Fig. 10).
CAUTION: Pry up with equal force on both sides of
shifter cable isolator bushings to avoid damaging
cable isolator bushings.
Fig. 5 Transaxle Drain Plug
Fig. 6 Shifter Knob
Fig. 7 Shifter Boot
NS/GSA±598 MANUAL TRANSAXLE 21 - 5
SERVICE PROCEDURES (Continued)

REVERSE SHIFT LEVER
REMOVAL
(1) Remove reverse shift lever E-clip.
(2) Remove the flat and wave washers.
(3) Remove the reverse shift lever from the mount-
ing stud.
INSTALLATION
(1) Position the reverse shift lever onto the mount-
ing stud.
(2) Install the washers onto the mounting stud.
(3) Install the E-clip.
CLEANING AND INSPECTION
TRANSAXLE
Clean the gears, bearings, shafts, synchronizers,
thrust washers, oil feeder, shift mechanism, gear
case, and bellhousing with solvent. Dry all parts
except the bearings with compressed air. Allow thebearings to either air dry or wipe them dry with
clean shop towels.
Inspect the gears, bearings, shafts and thrust
washers. Replace the bearings and cups if the rollers
are worn, chipped, cracked, flat spotted, or brin-
nelled, or if the bearing cage is damaged or distorted.
Replace the thrust washers if cracked, chipped, or
worn. Replace the gears if the teeth are chipped,
cracked, or worn thin. Inspect the synchronizers.
Replace the sleeve if worn or damaged in any way.
Replace the stop rings if the friction material is
burned, flaking off, or worn. Check the condition of
the synchro struts and springs. Replace these parts if
worn, cracked, or distorted.
SYNCHRONIZER
CLEAN
Do not attempt to clean the blocking rings in sol-
vent. The friction material will become contaminated.
Place synchronizer components in a suitable holder
and clean with solvent. Air dry.
INSPECT
Proper inspection of components involve:
²Teeth, for wear, scuffed, nicked, burred, or bro-
ken teeth
²Struts, for wear or distortion
²Springs, for distortion, cracks, or wear
If any of these conditions exist in these compo-
nents, replace as necessary.
ADJUSTMENTS
GEARSHIFT CROSSOVER CABLE
Before replacing the gearshift cables for a hard-
shifting complaint, disconnect both cables at the
transaxle. Then, from the driver's seat, manually
operate the gearshift lever through all gear ranges. If
the gearshift lever moves smoothly, the cable(s)
should NOT be replaced. If the gear lever binds
replace the cable that is causing the binding condi-
tion. If the problem still exists, check the crossover
cable adjustment (Fig. 210).
(1) Working over the left front fender, remove the
auxiliary vent from the selector shaft housing (Fig.
211).
(2) Locate the gearshift lock pin that has been
included in the new vehicle packet located in the
glove box.
(3) Place transaxle gearshift in the neutral posi-
tion.
(4) Insert lock pin (so long end is down) into same
threaded hole (Fig. 212). A hole in the selector shaft
will align with the lock pin, allowing the lock pin to
Fig. 208 Slide Hammer 3752
Fig. 209 Shift Rail Bushing Removal
21 - 52 A±598 MANUAL TRANSAXLENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

SPECIAL TOOLS
A-598 (T-750) MANUAL TRANSAXLE
A-558 MANUAL TRANSAXLEÐRHD VEHICLES
A-558 MANUAL TRANSAXLE FLUID FILL
The fluid level should be within 3.175mm (1/8 inch)
from the bottom of the transaxle fill hole (vehicle must
be level when checking).
Fill transaxle to proper level with SAE 5W-30 engine oil,
meeting SG and/or SG-CD qualifications. G5 SAE
10W-40 engine oil is a suitable service fill alternative.
TRANSAXLEMETRIC MEA-
SUREU.S. MEASURE
A-558 1.9-2.2 Liters 2.0-2.3 Quarts
Bearing Splitter 1130
Slide Hammer 3752
Bearing Remover 5066
Gear Holder 6252
Bearing Remover 6786
Bearing Remover 6787
21 - 60 A±598 MANUAL TRANSAXLENS/GS

SERVICE PROCEDURES
WHEEL INSTALLATION
To install the wheel, first position it properly on
the mounting surface of the hub using the hub pilot
as a guide. All wheel nuts should be lightly tightened
before progressively tightening them in the proper
sequence (Fig. 7). Then fully tighten the wheel nuts
in the proper sequence (Fig. 7) to a torque of 135
N´m (100 ft. lbs.). Never use oil or grease on studs or
nuts.
TIRE AND WHEEL BALANCE
Balancing need is indicated by vibration of seats,
floor pan, or steering wheel. The vibration will be
noticed mostly when driving over 90 km/h (55 mph)
on a smooth road.
It is recommended that a two plane dynamic bal-
ancer be used when a wheel and tire assembly
require balancing. Static balancing should be used
only when a two plane balancer is not available.
Off-vehicle tire and wheel balancing is recom-
mended to be used on this vehicle.
NOTE: If on vehicle equipment is being used to bal-
ance the tire /wheel assemblies, remove the oppo-
site tire/wheel from the vehicle.
For static balancing, find the location of heavy spot
on tire/wheel causing the imbalance. Counter balance
wheel directly opposite the heavy spot. Determine
weight required to counterbalance the area of imbal-
ance. Place half of this weight on theinnerrim
flange and the other half on theouterrim flange
(Fig. 8).
For dynamic balancing, the balancing equipment is
designed to indicate the location and amount of
weight to be applied to both the inner and outer rim
flanges (Fig. 9).
Fig. 5 Checking Wheel Radial Run Out
Fig. 6 Checking Wheel Lateral Run Out
Fig. 7 Tightening Wheel Nuts
NSTIRES AND WHEELS 22 - 11
DIAGNOSIS AND TESTING (Continued)

HEATING AND AIR CONDITIONING
CONTENTS
page page
FRONT HEATING AND AIR CONDITIONING
SYSTEM............................... 1REAR HEATING AND AIR CONDITIONING
SYSTEM.............................. 41
FRONT HEATING AND AIR CONDITIONING SYSTEM
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 2
SAFETY PRECAUTIONS AND WARNINGS...... 2
DESCRIPTION AND OPERATION
A/C PRESSURE TRANSDUCER.............. 2
A/C SERVICE PORTS..................... 2
AIR DISTRIBUTION DUCTS................. 2
COMPRESSOR HIGH-PRESSURE RELIEF
VALVE................................ 3
CONDENSATE DRAIN..................... 3
ENGINE COOLING SYSTEM REQUIREMENTS . . 3
EVAPORATOR PROBE..................... 3
HANDLING TUBING AND FITTINGS........... 3
HVAC CONTROL MODULE................. 4
REAR BLOWER SPEED SWITCH............ 3
SIDE DOOR HEATER A/C OUTLETS.......... 4
SIDE WINDOW DEMISTER................. 4
SYSTEM AIRFLOW....................... 4
SYSTEM OIL LEVEL...................... 5
DIAGNOSIS AND TESTING
A/C PERFORMANCE TEST................ 12
A/C PRESSURE TRANSDUCER............. 12
ACTUATOR CALIBRATION/DIAGNOSTICS AND
COOLDOWN TEST...................... 6
BLOWER MOTOR AND WHEEL ASSEMBLY.... 13
COMPRESSOR CLUTCH/COIL.............. 13
COMPRESSOR NOISE DIAGNOSIS.......... 13
EXPANSION VALVE...................... 13
HEATER PERFORMANCE TEST............ 15
HVAC CONTROL DIAGNOSTIC CONDITIONS . . . 9
SYSTEM CHARGE LEVEL TEST............ 16SERVICE PROCEDURES
CHARGING REFRIGERANT SYSTEM........ 17
EVACUATING REFRIGERANT SYSTEM....... 18
R-134a REFRIGERANT................... 16
STICKING HVAC CONTROL MODULE PUSH
BUTTONS............................ 19
SYSTEM LEAK CHECKING................ 19
THERMOCOUPLE PROBE................. 19
REMOVAL AND INSTALLATION
A/C PRESSURE TRANSDUCER............. 20
A/C SERVICE PORTS.................... 20
BLEND-AIR DOOR ACTUATOR............. 20
BLOWER MOTOR AND WHEEL ASSEMBLY.... 21
BLOWER MOTOR RESISTOR BLOCK........ 21
BLOWER MOTOR WHEEL................. 22
COMPRESSOR CLUTCH/COIL.............. 23
COMPRESSOR......................... 23
CONDENSER ASSEMBLY................. 25
DISCHARGE LINE....................... 26
EVAPORATOR PROBE.................... 27
EXPANSION VALVE...................... 28
FILTER-DRIER ASSEMBLY................. 28
HEATER A/C UNIT HOUSING............... 29
HEATER CORE......................... 30
HEATER HOSES........................ 31
LIQUID LINE........................... 32
MODE DOOR ACTUATOR................. 32
RECIRC DOOR ACTUATOR................ 34
SIDE WINDOW DEMISTER DUCTS.......... 33
SUCTION LINE.......................... 33
DISASSEMBLY AND ASSEMBLY
HEATER A/C UNIT RECONDITION........... 34
NSHEATING AND AIR CONDITIONING 24 - 1

unit housing. On air conditioned vehicles, the air
passes through the evaporator. At this point the air
flow can be directed either through or around the
heater core. This is done by adjusting the blend- air
door with the TEMP control on the control head. An
optional zone control HVAC control module is avail-
able. This unit has dual blend-air doors that can be
regulated independently of each other. The tempera-
ture setting can be different from driver's side to pas-
senger side. After the air passes the blend-air door(s),
the air flow can then be directed from the Panel,
Floor, and Defrost outlets. Air flow velocity can be
adjusted with the blower speed selector switch on the
control head.
Ambient air intake can be shut off by closing the
recirculating air door. This will recirculate the air
that is already inside the vehicle. This is done by
depressing the Recirc. button on the control head. On
air conditioned vehicles, moving the control to Mix or
Defrost depresses the A/C button and will engage the
compressor. This will send refrigerant through the
evaporator, and remove heat and humidity from the
air before it goes through the heater core.
CAUTION: In cold weather, use of the Recirculation
mode may lead to excessive window fogging. The
Recirculation mode is automatically deactivated in
Mix and Defrost modes to improve window clearing
operation.
SYSTEM OIL LEVEL
It is important to have the correct amount of oil in
the A/C system to ensure proper lubrication of the
compressor. Too little oil will result in damage to the
compressor. Too much oil will reduce the cooling
capacity of the system and consequently result in
higher discharge air temperatures.NOTE: The oil used in the compressor is ND8 PAG
R134a refrigerant oil. Only refrigerant oil of the
same type should be used to service the system.
Do not use any other oil. The oil container should
be kept tightly capped until it is ready for use.
Tightly cap afterwards to prevent contamination
from dirt and moisture. Refrigerant oil will quickly
absorb any moisture it comes in contact with. Spe-
cial 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.
It will not be necessary to check oil level in the
compressor or to add oil unless there has been an oil
loss. Oil loss at a leak point will be evident by the
presence of a wet, shiny surface around the leak.
REFRIGERANT OIL LEVEL CHECK
When an air conditioning system is first assem-
bled, 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, refer to
the Refrigerant Oil Capacities chart. When a compo-
nent 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 com-
pressor. 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 sys-
tem, 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).
Fig. 5 Demister Inlet
NSHEATING AND AIR CONDITIONING 24 - 5
DESCRIPTION AND OPERATION (Continued)

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 ND8 PAG (polyalka-
lene glycol).
SERVICING REFRIGERANT OIL LEVEL
(1) Using a refrigerant recovery machine, remove
refrigerant from the A/C system.
(2) Remove refrigerant lines from A/C compressor.
(3) Remove compressor from vehicle.
(4) From suction port on top of compressor, drain
refrigerant oil from compressor.
(5) Add system capacity minus the capacity of
components that have not been replaced through suc-
tion port on compressor. Refer to the Refrigerant Oil
Capacity Chart.
(6) Install compressor, connect refrigerant lines,
evacuate, and charge refrigerant system.
DIAGNOSIS AND TESTING
ACTUATOR CALIBRATION/DIAGNOSTICS AND
COOLDOWN TEST
GENERAL INFORMATION
If the HVAC control module is replaced, the Cali-
bration Diagnostic and Cooldown tests will need to
be performed. Once this group of tests have success-
fully passed, they can be performed individually. The
engine must be running during the test to provide
hot coolant for the heater, A/C compressor operation
and to assure that the actuators are calibrated cor-
rectly. The HVAC control module is capable of trou-
bleshooting the system in approximately 120 seconds.
If a condition is detected, an error code is displayed.
The error code cannot be erased until the condition is
repaired and the diagnostic test is performed. Check
wire before replacing components, refer to Group 8W,
Wiring Diagrams.CAUTION: Do not remove the actuators from the
Heater-A/C unit assembly with power applied.
Removal should only be done with the Ignition OFF.
The actuators have no mechanical stops to limit the
travel. If the actuator rotates and is not connected
to the unit assembly, it will become out of calibra-
tion.
ACTUATOR CALIBRATION
Mode, Blend and Zone (if equipped) door calibra-
tion compensates for mechanical variations in the
actuators, HVAC control module and its linkages. In-
vehicle calibration can be entered from the control's
front panel. If the REAR WIPE and INTERMIT-
TENT LED's flash simultaneously when Ignition is
cycled ON, the actuators have not been calibrated or
during the previous calibration a failure occurred
(Fig. 6) and (Fig. 7). Diagnostics will always occur
during Calibration Diagnostic and Cooldown test.
REFRIGERANT OIL CAPACITIES
Refrigerant
Oil Capaci-
tiesFront A/C Dual A/C
Component ml oz ml oz
Compressor 150 ml 5.0 oz 220 ml 7.4 oz
Filter-Drier 30 ml 1.0 oz 30 ml 1.0 oz
Condenser 30 ml 1.0 oz 30 ml 1.0 oz
Evaporator 60 ml 2.0 oz 60 ml 2 .0 oz
Rear Evap. N/A N/A 60 ml 2.0 oz
Fig. 6 Radio Bezel and HVAC Control
24 - 6 HEATING AND AIR CONDITIONINGNS
DESCRIPTION AND OPERATION (Continued)