1996 CHRYSLER VOYAGER ignition

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

CAUTION: When installing steering wheel puller
bolts in steering wheel, (Fig. 8) do not thread bolt
into steering wheel more than a half inch. If bolts
are threaded into the steering wheel more than a
half inch they will contact and damage the clock-
spring.
(11) Remove the steering wheel from steering col-
umn shaft using Puller, Special Tool, Snap-On
CJ2001JP or an equivalent (Fig. 8).
CAUTION: The upper and lower steering column
shrouds are held together using retaining clips.
When separating and removing the shrouds from
the steering column be careful not to break the
retaining clips off the shrouds
(12) Remove the 3 screws (Fig. 9) attaching the
upper and lower shrouds to the steering column.
Then remove the upper and lower shrouds (Fig. 9)
from the steering column.(13) Remove the vehicle wiring harness connectors
(Fig. 10) from the clock spring assembly.
CAUTION: Do not rotate the clock spring after it is
removed from the multifunction switch.
(14) Remove the clock spring from the multi-func-
tion switch.
(15) Remove the vehicle wiring harness connector
from the top of the multi-function switch (Fig. 11).
(16) Remove the screw (Fig. 12) attaching the
multi-function switch housing to the tilt head of the
steering column assembly.
(17) Remove the multi-function switch (Fig. 12)
from the tilt head of the steering column assembly.
(18) Remove the vehicle wiring harness connector
from the key cylinder halo light (Fig. 13).
(19) Remove the 3 wiring harness connectors from
the ignition switch (Fig. 14).
Fig. 8 Removing Steering Wheel From Steering
Column Shaft
Fig. 9 Steering Column Shrouds
Fig. 10 Wiring Harness Connections To Clock
Spring
Fig. 11 Wiring Harness Connection To Multi-
Function Switch
19 - 40 STEERINGNS
REMOVAL AND INSTALLATION (Continued)

(20) If the vehicle is equipped with a 3 speed non-
electronic transmission, remove the PRNDL actuat-
ing cable from the pin on the gear shifter (Fig. 15).PRNDL actuating cable MUST be removed from
the pin on the gear shifter prior to removing
the gear selector cable from the gear shifter.
(21) Remove the attaching clip (Fig. 15) for the
PRNDL actuating cable from the steering column/
shift cable bracket.
(22) Remove the gear selector cable from the gear
shifter the steering column (Fig. 16). Gear selector
cable is removed from pin on shift module bycare-
fullyprying it off with a screw driver (Fig. 16).
(23) Remove the gear selector cable and its mount-
ing bracket as an assembly, from the upper mounting
bracket for the steering column (Fig. 17).
(24) Remove the instrument cluster trim bezel
(Fig. 18) from the instrument panel. The trim bezel
is mounted to the instrument panel using 2 attaching
screws and retaining clips.
(25) Remove the steering column fixed shroud
from the steering column assembly (Fig. 19). Shroud
Fig. 12 Multi-Function Switch Mounting Housing
Attaching Screw
Fig. 13 Wiring Harness Connection To Halo Light
Fig. 14 Ignition Switch Wiring Harness Connections
Fig. 15 PRNDL Actuating Cable At Steering Column
Fig. 16 Gear Selector Cable Removal From Shift
Module
NSSTEERING 19 - 41
REMOVAL AND INSTALLATION (Continued)

(28) Remove steering column assembly from vehi-
cle. Use care to avoid damage to paint or interior
trim.
INSTALL
(1) Ensure the plastic mounting capsules (Fig. 22)
are installed in the upper mounting bracket of the
steering column. Mounting capsules must be
installed as shown in (Fig. 22) with the thicker edge
of the capsule facing the top of the steering column.
(2) Install steering column assembly into its open-
ing in instrument panel. Install the steering column
lower bracket so the bracket is squarely installed on
its mounting studs (Fig. 21). Then align and install
steering column upper bracket on its mounting studs
(Fig. 21). Tighten the 4 steering column assembly
mounting nut/washer assemblies to a torque of 12
N´m (105 in. lbs.).
(3) Assemble the steering column shaft coupler
(Fig. 20) onto the steering gear intermediate coupler.
Install steering column coupler to intermediate shaft
retaining pinch bolt (Fig. 20). Tighten the pinch bolt
nut to a torque of 28 N´m (250 in. lbs.). Install safety
pin (Fig. 20) in steering column shaft coupler pinch
bolt.
(4) Install the gear slector cable and its mounting
bracket on the upper mounting bracket of the steer-
ing column (Fig. 17). Install and securely tighten the
mounting bracket attaching bolt.
(5) Install the gear selector cable on the pin of the
gear shifter (Fig. 16).
(6) If the vehicle is equipped with a 3 speed non-
electronic transmission, install the PRNDL actuating
cable on the gear shifter pin after the gear selector
cable is installing (Fig. 15).
(7) If the vehicle is equipped with a 3 speed non-
electronic transmission, install the attaching clip
(Fig. 15) for the PRNDL actuating cable on the steer-ing column/shift cable bracket. Cable guide tube will
bow toward passenger side of vehicle. Verify that
actuating cable is operating correctly, then slip the
loop on the end of the cable over end of pin on shift
lever and install in groove (Fig. 15).
(8) Install the steering column fixed shroud on the
steering column assembly (Fig. 19). Shroud is
mounted to steering column using 2 attaching screws
accessed from top of fixed shroud.
(9) Install the instrument cluster trim bezel (Fig.
18) on the instrument panel. The trim bezel is
mounted to the instrument panel using 2 attaching
screws (Fig. 18) and retaining clips.
(10) Install the 3 wiring harness connectors on the
ignition switch (Fig. 14).
(11) Install the vehicle wiring harness connector
into the key cylinder halo light (Fig. 13).
(12) Install the multi-function switch (Fig. 12) on
the tilt head of the steering column assembly. Then
install screw (Fig. 12) attaching multi-function
switch to tilt head of steering column.
(13) Install the vehicle wiring harness connector
on the multi-function switch (Fig. 11). Be sure latch
on connector is fully engaged with tab on switch.
(14) Install the clock spring on the multi-function
switch.
(15) Install the vehicle wiring harness connector
(Fig. 10) on the clock spring assembly.
(16) Install the lower steering column shroud on
the tilt head of the steering column (Fig. 23). Install
and securely tighten the screw attaching the lower
shroud to the tilt head.
(17) Install the upper steering column shroud on
the tilt head of the steering column (Fig. 24). Install
and securely tighten the 2 screws attaching the
upper shroud to the lower shroud.
Fig. 22 Mounting Capsules Correctly Installed On
Steering Column
Fig. 23 Lower Steering Column Shroud Installed
NSSTEERING 19 - 43
REMOVAL AND INSTALLATION (Continued)

(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)

Inspect all valve springs for distortion and col-
lapsed coils. Inspect all valves and plugs for burrs,
nicks, and scores. Small nicks and scores may be
removed with crocus cloth, providing extreme care is
taken not to round off sharp edges. The sharpness of
these edges is vitally important. It prevents foreign
matter from lodging between valve and valve body.
This reduces the possibility of sticking. Inspect all
valves and plugs for freedom of operation in valve
body bores.
When bores, valves, and plugs are clean and dry,
the valves and plugs should fall freely in the bores.
The valve body bores do not change its dimensions
with use. Therefore, a valve body that was function-
ing properly when vehicle was new, will operate cor-
rectly if it is properly and thoroughly cleaned. There
is no need to replace valve body unless it is damaged
in handling.
ADJUSTMENTS
GEARSHIFT CABLE ADJUSTMENT
Lift and rotate the gearshift hand lever into the
park (P) gate position and remove the ignition key.
This confirms the shift lever is in the gated park (P)
position.
After confirming the park gate position, turn the
ignition switch. If the starter will operate, the park
gate position is correct. Move the shift lever into the
neutral (N) position. If the starter will operate in this
position, the linkage is properly adjusted. If the
starter fails to operate in either position, linkage
adjustment is required.
(1) Park the vehicle on level ground and set the
parking brake.
(2) Place the gearshift lever in park (P) gate posi-
tion and remove key.
(3) Loosen the cable adjustment screw at the tran-
saxle operating lever (Fig. 160).
(4) Pull the transaxle operating lever fully forward
to the park detent position.
(5) Release the park brake, then rock the vehicle
to assure it is in park lock. Reset the park brake.
(6) Tighten the cable adjustment screw to 8 N´m
(70 in. lbs.). Gearshift cable should now be properly
adjusted.
(7) Verify PRNDL indicator still displays the corre-
sponding gear completely. If not, readjustment of
PRNDL may be required.
(8) Check adjustment by using the preceding pro-
cedure.
THROTTLE PRESSURE LINKAGE ADJUSTMENT
The throttle pressure rod adjustment is very
important to proper transaxle operation. This adjust-
ment positions a valve which controls shift speed,shift quality, and part throttle downshift sensitivity.
If the setting is too short, early shifts and slippage
between shifts may occur. If the setting is too long,
shifts may be delayed and part throttle downshifts
may be very sensitive.
With engine at operating temperature, adjust idle
speed of engine using a tachometer. Refer to Group
14, Fuel System for idle speed Specifications and
adjustment.
ROD ADJUSTMENT PROCEDURE
(1) Perform transaxle throttle pressure adjustment
while engine is at normal operating temperature.
(2) Loosen adjustment swivel lock screw.
(3) To insure proper adjustment, swivel must be
free to slide along flat end of throttle rod. Disassem-
ble and clean or repair parts to assure free action, if
necessary.
(4) Hold transaxle throttle lever firmly toward
engine, against its internal stop. Tighten swivel lock
screw to 11 N´m (100 in. lbs.)
(5) The adjustment is finished and linkage back-
lash was automatically removed by the preload
spring.
(6) I
f lubrication is required see Group 0, Lubrica-
tion.
BAND ADJUSTMENT
KICKDOWN BAND (FRONT)
The kickdown band adjusting screw is located on
left side (top front) of the transaxle case.
(1) Loosen locknut and back off nut approximately
five turns. Test adjusting screw for free turning in
the transaxle case.
(2) Using wrench, tighten adjusting screw to 8
N´m (72 in. lbs.).
Fig. 160 Gearshift Cable Adjustment
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 51
CLEANING AND INSPECTION (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)

(6) Attach cable eyelet fitting onto the transaxle
operating lever.
(7) Complete adjustment using the gearshift cable
adjustment procedure.
ADJUSTMENT
Lift and rotate the gearshift hand lever into the
park (P) gate position and remove the ignition key.
This confirms the shift lever is in the gated park (P)
position.
After confirming the park gate position, turn the
ignition switch. If the starter will operate, the park
gate position is correct. Move the shift lever into the
neutral (N) position. If the starter will operate in this
position, the linkage is properly adjusted. If the
starter fails to operate in either position, linkage
adjustment is required.
(1) Park the vehicle on level ground and set the
parking brake.
(2) Place the gearshift lever in park (P) gate posi-
tion and remove key.(3) Loosen the cable adjustment screw at the tran-
saxle operating lever (Fig. 10).
(4) Pull the transaxle operating lever fully forward
to the park detent position.
(5) Release the park brake, then rock the vehicle
to assure it is in park lock. Reset the park brake.
(6) Tighten the cable adjustment screw to 8 N´m
(70 in. lbs.). Gearshift cable should now be properly
adjusted.
(7) Check adjustment by using the preceding pro-
cedure.
MANUAL VALVE LEVER (SHIFT LEVER)
REMOVAL
(1) Remove shift cable from lever (Fig. 11).
(2) Loosen the lever mounting bolt (Fig. 12). Do
not remove bolt (not necessary).
(3) Pull up on lever and remove.
INSTALLATION
(1) For installation, reverse removal procedure.
Fig. 8 Remove Cable From Bracket
Fig. 9 Instrument Panel Silencer
Fig. 10 Gearshift Cable
Fig. 11 Shift Cable
21 - 84 TRANSAXLE AND POWER TRANSFER UNITNS
REMOVAL AND INSTALLATION (Continued)