1996 CHRYSLER VOYAGER warning

DISASSEMBLY AND ASSEMBLY
POWER STEERING PUMP PULLEY
DISASSEMBLY
(1) Remove the pulley from the shaft of the power
steering pump using Puller C-4333 or C-4068 (Fig.
33).
CAUTION: Do not hammer on power steering
pump pulley. This will damage the pulley and the
power steering pump.
(2) Replace pulley if it is found to be bent, cracked,
or loose.
ASSEMBLY
(1) Install the pulley with Installer C-4063 (Fig.
34). Do not use the tool adapters.
(2) Ensure that the tool and the pulley remain
aligned with the pump shaft. Prevent the pulley from
being cocked on the shaft.(3) Force pulley flush with the end of the power
steering pump shaft (Fig. 35).
(4) With serpentine belts, run engine until warm
(5 min.) and note any belt chirp. If chirp exists, move
pulley outward approximately 0.5 mm (0.020 in.). If
noise increases, press on 1.0 mm (0.040 in.).Be
careful that pulley does not contact mounting
bolts.
POWER STEERING PUMP FLOW CONTROL VALVE
SEAL
DISASSEMBLE
WARNING: POWER STEERING OIL, ENGINE
PARTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(3) Raise vehicle See Hoisting, Group 0. Put oil
drain pan under vehicle to catch power steering fluid.
(4) Raise the heat sleeve (Fig. 36) on the power
steering return hose to expose the return hose to
steel tube connection. Remove hose clamp from
power steering fluid return hose (Fig. 36). Remove
power steering return hose from steel tube and allow
remaining power steering fluid to drain from power
steering pump and reservoir.
(5) Remove the power steering fluid pressure line
from the power steering pump pressure fitting (Fig.
37). Drain excess power steering fluid from hose.
Fig. 33 Pulley Removal
Fig. 34 Pulley Installation
Fig. 35 Pulley To Pump Shaft Location
NSSTEERING 19 - 23

STEERING COLUMN
INDEX
page page
DESCRIPTION AND OPERATION
STEERING COLUMN DESCRIPTION......... 36
DIAGNOSIS AND TESTING
STEERING COLUMN..................... 38
SERVICE PROCEDURES
STEERING COLUMN SERVICE PROCEDURE
WARNINGS........................... 38REMOVAL AND INSTALLATION
STEERING COLUMN ASSEMBLY............ 38
SPECIFICATIONS
STEERING COLUMN FASTENER TORQUE
SPECIFICATIONS...................... 45
DESCRIPTION AND OPERATION
STEERING COLUMN DESCRIPTION
The steering column (Fig. 1) has been designed to
be serviced only as a complete assembly, if a compo-
nent of the steering column is defective. The only
replaceable components of the steering columnassembly are the key cylinder, ignition switch, multi-
function switch, clockspring, halo lamp, speed control
switches, driver airbag, trim shrouds and steering
wheel. These replaceable components of the steering
column can be serviced without requiring removal of
the steering column from the vehicle.
Fig. 1 Steering Column Assembly Components
19 - 36 STEERINGNS

DIAGNOSIS AND TESTING
STEERING COLUMN
For diagnosis of conditions relating to the steering
column, refer to the steering system diagnosis charts,
in the diagnosis and testing section at the beginning
of this group.
SERVICE PROCEDURES
STEERING COLUMN SERVICE PROCEDURE
WARNINGS
WARNING: BEFORE BEGINNING ANY SERVICE
PROCEDURES THAT INVOLVES REMOVING THE
AIR BAG. REMOVE AND ISOLATE THE NEGATIVE
(-) BATTERY CABLE (GROUND) FROM THE VEHI-
CLE BATTERY. THIS IS THE ONLY SURE WAY TO
DISABLE THE AIR BAG SYSTEM. FAILURE TO DO
THIS COULD RESULT IN ACCIDENTAL AIR BAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
WARNING: THE AIR BAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIR BAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. FAILURE TO DO SO
COULD RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIR BAG AND POSSIBLE PERSONAL INJURY.
THE FASTENERS, SCREWS, AND BOLTS, ORIGI-
NALLY USED FOR THE AIR BAG COMPONENTS,
HAVE SPECIAL COATINGS AND ARE SPECIFI-
CALLY DESIGNED FOR THE AIR BAG SYSTEM.
THEY MUST NEVER BE REPLACED WITH ANY SUB-
STITUTES. ANYTIME A NEW FASTENER IS
NEEDED, REPLACE WITH THE CORRECT FASTEN-
ERS PROVIDED IN THE SERVICE PACKAGE OR
FASTENERS LISTED IN THE PARTS BOOKS.
BEFORE SERVICING A STEERING COLUMN
EQUIPPED WITH AN AIR BAG, REFER TO GROUP
8M, ELECTRICAL FOR PROPER AND SAFE SER-
VICE PROCEDURES.
NOTE: Safety goggles should be worn at all times
when working on steering columns.
CAUTION: Disconnect negative (ground) cable
from the battery, before servicing any column com-
ponent.CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Damage will
occur.
REMOVAL AND INSTALLATION
STEERING COLUMN ASSEMBLY
To service the steering wheel and its components
or the air bag, refer to Group 8M, Restraint Systems.
Follow all WARNINGS.
To service the switches, refer to the appropriate
section of Group 8, Electrical.
To replace the steering column assembly, refer to
the steering column removal procedure.
REMOVE
(1) Make sure the front wheels of the vehicle are
in thestraight aheadposition before beginning the
column removal procedure.
(2) Disconnect negative (ground) cable from the
battery and isolate cable from battery terminal.
(3) Remove the screws attaching the lower steer-
ing column cover to the instrument panel (Fig. 2).
Remove the lower trim panel from the lower instru-
ment panel.
(4) Remove the park brake pedal release cable
from the park brake release lever (Fig. 3).
(5) Remove the 10 bolts attaching the steering col-
umn cover liner (Fig. 4) to the instrument panel.
Remove the steering column cover liner from the
lower instrument panel.
(6) Rotate key cylinder to the lock position and
remove key. Rotate the steering wheel a half turn to
the left until the steering column lock engages keep-
ing the steering column in the locked position (Fig.
5).
Fig. 2 Lower Steering Column Cover Attachment
Locations
19 - 38 STEERINGNS

STEERING
CONTENTS
page
POWER STEERINGÐ2.5L VM DIESEL....... 1
POWER STEERINGÐ2.5L VM DIESEL
INDEX
page page
GENERAL INFORMATION
POWER STEERING GEAR................ 1
POWER STEERING PUMP................ 1
STEERING GEAR OPERATIONÐRHD & LHD
VEHICLES........................... 1SERVICE PROCEDURES
POWER STEERING PUMP ± INITIAL
OPERATION.......................... 1
REMOVAL AND INSTALLATION
POWER STEERING PUMPÐ2.5L DIESEL..... 2
GENERAL INFORMATION
POWER STEERING PUMP
The power steering pump used with the 2.5L VM
Diesel engine operates the same way as the power
steering pump used with the 2.5/4.0L gasoline
engines. Refer to the Description and Operation sec-
tion for the 2.5/4.0L gasoline engine power steering
pump for more information.
STEERING GEAR OPERATIONÐRHD & LHD
VEHICLES
NOTE: The power steering gear should NOT be ser-
viced or adjusted. If a malfunction or oil leak
occurs, the complete steering gear should be
replaced.
Refer to the Power Steering Gear in group 19 for
more information
POWER STEERING GEAR
SERVICE PROCEDURES
POWER STEERING PUMP ± INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal temperature.
(1) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two minutes.
(2) Start the engine and let run for a few seconds
then turn engine off.
(3) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
ning the engine.
Fig. 1 Power Steering GearÐRHD Vehicles
NS/GSSTEERING 19 - 1

(13) Remove the pan and clean all sealant from
the pan and transaxle mating surfaces. Clean the
magnet and the inside of the pan.
(14) Separate the filter from the valve body to
allow additional fluid to drain from the transaxle.
Inspect the filter O-ring for any damage and replace
as necessary.
(15) After the transaxle has stopped draining,
reinstall the filter and O-ring.
(16) Apply a 1/8 inch bead of Mopar RTV Sealant
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. Tighten the
bolts to 19 N²m (165 in. lbs.).
(17) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(18) Start the engine and allow it to idle for a min-
imum 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.
(19) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(20) Recheck the fluid level after the transaxle is
at normal operating temperature. The level should be
in the HOT range.
FLUID DRAIN AND REFILL
(1) Raise vehicle on a hoist (See Group 0, Lubrica-
tion). 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 gasket on bottom of the
valve body and tighten retaining screws to 5 N´m (40
inch-pounds).
(4) Clean the oil pan and magnet. Reinstall pan
using new sealant. Tighten oil pan bolts to 19 N´m
(165 in. lbs.).
(5) Pour four quarts of Mopar ATF PLUS 3 (Auto-
matic Transmission Fluid) Type 7176 through the
dipstick opening.
(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.
(8) Recheck fluid level after transaxle is at normal
operating temperature. The level should be in the
HOT region.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum transaxle
case and valve body can be repaired by the use of Heli-
Coils, or equivalent. This repair consists of drilling out
the worn-out damaged threads. Then tapping the hole
with a Heli-Coil tap, or equivalent, and installing a
Heli-Coil insert, or equivalent, into the hole. This
brings the hole back to its original thread size.
Heli-Coil, or equivalent, tools and inserts are readily
available from most automotive parts suppliers.
FLUSHING COOLERS AND TUBES
When a transaxle failure has contaminated the
fluid, the oil cooler(s) must be flushed. The cooler
bypass valve in the transaxle must be replaced also.
The torque converter must also be replaced with an
exchange unit. This will ensure that metal particles
or sludged oil are not later transferred back into the
reconditioned (or replaced) transaxle.
The recommended procedure for flushing the cool-
ers and tubes is to use Tool 6906A Cooler Flusher.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1±1968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906A
(1) Remove cover plate filler plug on Tool 6906A.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906A.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
21 - 18 TRANSAXLE AND POWER TRANSFER UNITNS
SERVICE PROCEDURES (Continued)

NOTE: Use MoparTRTV sealant, or equivalent,
when installing differential bearing retainer.WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY
TO PREVENT IT FROM ROLLING OUT OF HOUSING.
Use MopartSilicone Rubber Adhesive Sealant, or
equivalent, when installing extension housing.
Fig. 145 Extension Bolts
Fig. 146 Remove or Install Extension Housing
Fig. 147 Differential and Extension
Fig. 148 Remove Differential Bearing Cone
(Extension Housing Side)
Fig. 149 Position Bearing Cone Onto Differential
Fig. 150 Install Differential Bearing Cone
21 - 48 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)

WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1±1968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906A
(1) Remove cover plate filler plug on Tool 6906A.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906A.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
(5) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Turn pump ON for two to three minutes to
flush cooler(s) and lines. Monitor pressure readings
and clear return lines. Pressure readings should sta-
bilize below 20 psi. for vehicles equipped with a sin-
gle cooler and 30 psi. for vehicles equipped with dual
coolers. If flow is intermittent or exceeds these pres-
sures, replace cooler.
(8) Turn pump OFF.
(9) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(10) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(11) Place CLEAR suction line into a one quart
container of MopartATF PLUS 3 Type 7176 auto-
matic transmission fluid.
(12) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. Thispurges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(13) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
OIL PUMP VOLUME CHECK
After the new or repaired transmission has been
installed, fill to the proper level with Mopar ATF
PLUS 3 (Type 7176) automatic transmission fluid.
The volume should be checked using the following
procedure:
(1) Disconnect theFrom coolerline at the trans-
mission and place a collecting container under the
disconnected line.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Run the engineat curb idle speed, with the
shift selector in neutral.
(3) If fluid flow is intermittent or it takes more
than 20 seconds to collect one quart of ATF, discon-
nect theTo Coolerline at the transaxle.
(4) Refill the transaxle to proper level and recheck
pump volume.
(5) If flow is found to be within acceptable limits,
replace the cooler. Then fill transmission to the
proper level, using Mopar ATF PLUS 3 (Type 7176)
automatic transmission fluid.
(6) If fluid flow is still found to be inadequate,
check the line pressure using the Transaxle Hydrau-
lic Pressure Test procedure.
(7) Check the cooler for debris on the external sur-
faces. Clean as necessary.
TRANSAXLE QUICK LEARN PROCEDURE
The quick learn procedure requires the use of the
DRBIII scan tool.
This program allows the electronic transaxle sys-
tem to recalibrate itself. This will provide the best
possible transaxle operation. The quick learn proce-
dure should be performed if any of the following pro-
cedures are performed:
²Transaxle Assembly Replacement
²Transmission Control Module Replacement
²Solenoid Pack Replacement
²Clutch Plate and/or Seal Replacement
²Valve Body Replacement or Recondition
To perform the Quick Learn Procedure, the follow-
ing conditions must be met:
²The brakes must be applied
²The engine speed must be above 500 rpm
²The throttle angle (TPS) must be less than 3
degrees
21 - 82 TRANSAXLE AND POWER TRANSFER UNITNS
SERVICE PROCEDURES (Continued)

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 bear-
ing cone on the extension housing side.
(5) Use Miller Special Tool 5048, 5048-4 Collets,
and L-4539-2 Button to remove the differential bear-
ing cone on the bearing retainer side (Fig. 289) (Fig.
290) (Fig. 291).
(6) Using Miller Special Tool L-4518, remove the
differential bearing race from the extension housing.
(7) Using Miller Special Tool 6062A, remove the
differential bearing race from the bearing retainer
(Fig. 292) (Fig. 293).
Fig. 288 Remove Bearing Retainer
Fig. 289 Position Button and Collets Onto
Differential and Bearing (Ring Gear Side)
Fig. 290 Position Tool 5048 Over Button and Collets
at Differential Bearing (Ring Gear Side)
Fig. 291 Remove Differential Bearing Cone (Ring
Gear Side)
Fig. 292 Position Bearing Cup Remover Tool in
Retainer
21 - 140 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)