1996 CHRYSLER VOYAGER lock

INSTALLATION
If outside door handle replacement is necessary,
transfer lock cylinder from the original handle to the
new one.
(1) Place outside door handle in position on vehi-
cle.
(2) Install nuts to hold outside door handle to door
outer panel (Fig. 23).
(3) Insert lock linkage into door latch.
(4) Engage clip to hold door lock linkage to latch.
(5) Insert latch linkage into door latch.
(6) Engage clip to hold door latch linkage to latch.
(7) Install push-in fasteners to hold VTSS switch
harness to inner door reinforcement bar, if equipped.
(8) Connect VTSS switch connector into door har-
ness, if equipped.
(9) Verify door latch operation.
(10) Install water shield and door trim panel.
FRONT DOOR REFLECTOR
REMOVAL
(1) Insert small, flat bladed pry tool between outer
edge of door reflector and HVAC outlet vent.
(2) Pry outward on outer edge of reflector.
(3) Remove reflector from vehicle (Fig. 24).
INSTALLATION
(1) Position reflector on vehicle.
(2) Insert inner edge of reflector into slot in HVAC
outlet vent.
(3) Snap outer edge of reflector into slot in HVAC
outlet vent.
FRONT DOOR SILL PLATE
REMOVAL
(1) Using trim stick (C-4755), disengage hidden
clips holding door sill plate from door sill.
(2) Remove sill plate from vehicle (Fig. 25).
INSTALLATION
(1) Place sill plate in position on vehicle.
(2) Align locating pins on backside of trim plate to
mating holes in door sill.
(3) Engage hidden clips to hold door sill plate to
door sill.
FRONT DOOR TRIM PANEL
REMOVAL
(1) Using a trim stick (C-4755), pry courtesy lamp
from door trim.
(2) Disconnect wire connector from courtesy lamp.
(3) If equipped, remove screws attaching door
assist handle to inner door panel.
(4) If equipped, remove screw attaching door pull
cup to inner door panel.
(5) If equipped, remove screws attaching trim
panel to door from below map pocket.
(6) If equipped, remove window crank.
(7) Using a trim stick, remove screw cover from
switch panel.
(8) Remove screws attaching switch panel to door
trim.
(9) Remove power accessary switch from door trim
(Fig. 26).
(10) Disconnect power switch from wire connector.
(11) If equipped, using a small, flat bladed pry
tool, remove memory seat/mirror switch and discon-
nect wire connector (Fig. 27).
(12) If equipped, remove screw holding door trim
to door panel from behind inside latch release han-
dle.
(13) Disengage clips attaching door trim to door
frame around perimeter of panel (Fig. 28).
(14) Lift trim panel upward to disengage flange
from inner belt molding at top of door.
Fig. 24 Front Door Reflector
Fig. 25 Door Sill Plate
23 - 34 BODYNS
REMOVAL AND INSTALLATION (Continued)

FUEL FILL DOOR BLOCKER LATCH
REMOVAL
(1) Remove left quarter trim panel.
(2) Remove water shield patch covering access hole
in C-pillar.
(3) Disengage latch release link from clip on fuel
fill blocker latch arm (Fig. 38).
(4) Remove screws holding fuel fill blocker latch to
C-pillar (Fig. 36).
(5) Remove fuel fill blocker latch from vehicle.
INSTALLATION
(1) Position fuel fill blocker latch on vehicle.
(2) Install screws to hold fuel fill blocker latch to
C-pillar.
(3) Engage latch release link into clip on fuel fill
blocker latch arm with fuel door in the closed posi-
tion.
(4) Install water shield patch to cover access hole
in C-pillar.
(5) Verify fuel fill blocker latch operation.
(6) Install left quarter trim panel.
FUEL FILL DOOR BLOCKER LATCH STRIKER
REMOVAL
(1) Remove sliding door trim panel.
(2) Remove watershield as necessary to access
striker
(3) Remove screws holding fuel fill door blocker
latch striker to sliding door rear end frame (Fig. 37).
(4) Remove fuel fill door blocker latch striker from
vehicle.
INSTALLATION
(1) Position fuel fill door blocker latch striker on
vehicle.
(2) Install screws to hold fuel fill door blocker latch
striker to sliding door rear end frame.(3) Install sliding door water shield.
(4) Install sliding door trim panel.
FUEL FILL DOOR BLOCKER LOCKOUT LINK
REMOVAL
(1) Remove left quarter trim panel.
(2) Remove water shield patch covering access hole
in C-pillar.
(3) Disengage fuel filler lockout link from clip on
fuel fill blocker latch arm (Fig. 38).
(4) Open fuel fill door.
(5) Remove screws holding fuel filler housing to
fuel filler tube neck.
(6) Reaching inside fuel filler housing, release clips
holding housing to outer quarter panel.
(7) Remove fuel filler housing and lockout link
from vehicle.
(8) Disengage clip holding link to fuel fill door
(Fig. 39).
(9) Remove link from fuel fill door.
Fig. 36 FUEL FILL DOOR BLOCKER LATCH
Fig. 37 Fuel Fill Door Blocker Latch Striker
Fig. 38 Fuel Filler Lockout Link at Latch Arm
23 - 38 BODYNS
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Insert link into clip on fuel fill door.
(2) Engage clip to hold link to fuel fill door.
(3) Insert lockout link through grommet in panel
between inner and outer quarter panel.
(4) Close fuel fill door.
(5) Install fuel filler housing to outer quarter
panel.
(6) Verify that all clips on fuel filler housing are
fully engaged to outer quarter panel.
(7) Engage fuel filler lockout link into clip on fuel
fill blocker latch arm.
(8) Install water shield patch covering access hole
in C-pillar.
(9) Install left quarter trim panel.
FUEL FILLER HOUSING ± WITH BLOCKER LATCH
REMOVAL
(1) Remove left quarter trim panel.
(2) Remove water shield patch covering access hole
in C-pillar.
(3) Disengage latch release link from clip on fuel
fill blocker latch arm (Fig. 38).
(4) Open fuel fill door.
(5) Remove screws holding fuel fill neck to fuel
filler housing.
(6) Position fuel fill neck out of the way.
(7) Reaching inside fuel filler housing, release clips
holding housing to quarter panel (Fig. 40).
(8) Remove fuel fill door from vehicle.
(9) Disengage clip holding link to fuel fill door
(Fig. 39).
(10) Remove link from fuel fill door.
INSTALLATION
(1) Install spring to housing and door
(2) Snap door into housing.
(3) Insert lockout link into clip on fuel fill door.
(4) Engage clip to hold link to fuel fill door.(5) Insert lockout link through grommet in panel
between inner and outer quarter panel.
(6) Close fuel fill door.
(7) Install fuel filler housing to outer quarter
panel.
(8) Verify that all clips on fuel filler housing are
fully engaged to outer quarter panel.
(9) Place fuel fill neck in position.
(10) Install screws to hold fuel fill neck to fuel
filler housing.
(11) Engage latch release link into clip on fuel fill
blocker latch arm.
(12) Verify fuel fill blocker latch operation.
(13) Install water shield patch to cover access hole
in C-pillar.
(14) Install left quarter trim panel.
GRILLE
REMOVAL
(1) Remove front fascia. Refer to Group 13, Frame
and Bumpers, for proper procedures.
(2) Disengage clips holding grille to front fascia
(Fig. 41).
(3) Remove plastic rivets holding grille to fascia.
(4) Remove grille from fascia.
INSTALLATION
(1) Position grille on fascia.
(2) Install plastic rivets to hold grille to fascia.
(3) Install clips to hold grille to fascia along bot-
tom of grille.
(4) Install front fascia. Refer to Group 13, Frame
and Bumpers, for proper procedure.
HEADLINING
REMOVAL
(1) Remove sun visors and vanity mirrors.
(2) Remove sun visor center supports.
(3) If equipped, remove coat hooks.
(4) If equipped, remove roof rail modules.
Fig. 39 Fuel Filler Lockout LinkFig. 40 Fuel Filler Housing and Door
NSBODY 23 - 39
REMOVAL AND INSTALLATION (Continued)

(5) Remove A-pillar trim covers.
(6) Remove B-pillar upper trim covers.
(7) Remove C-pillar upper trim covers.
(8) Remove D-pillar upper trim covers.
(9) Remove rear door opening header trim.
(10) If equipped, remove overhead console.
(11) If equipped, remove reading lamp.
(12) Remove dome lamp.
(13) Remove push-in locking fasteners holding
headlining to rear roof header (Fig. 42) or (Fig. 43).
(14) Remove headlining from roof.
(15) Extract headlining through rear door opening.
INSTALLATION
(1) Insert headlining through rear door opening.
(2) Place headlining in position on roof.
(3) Install left sun visor support.(4) Install push-in locking fasteners to hold head-
lining to rear roof header (Fig. 42) or (Fig. 43).
(5) Install right sun visor support.
(6) Install sun visors and vanity mirrors.
(7) If equipped, install roof rail modules.
(8) If equipped, install coat hooks.
(9) Install dome lamp.
(10) If equipped, install reading lamp.
(11) If equipped, install overhead console.
(12) Install rear door opening header trim.
(13) Install D-pillar upper trim covers.
(14) Install C-pillar upper trim covers.
(15) Install B-pillar upper trim covers.
(16) Install A-pillar trim covers.
HOOD
REMOVAL
(1) Raise hood to full up position.
(2) Mark all bolt and hinge attachment locations
with a grease pencil or other suitable device to pro-
vide reference marks for installation.
(3) Remove the top bolts holding hood to hinge and
loosen the bottom bolts until they can be removed by
hand (Fig. 44).
(4) With assistance from a helper at the opposite
side of the vehicle to support the hood, remove bot-
tom bolts holding hood to hinge.
(5) Remove the hood from the vehicle.
INSTALLATION
(1) Place hood in position on vehicle. With assis-
tance from a helper at the opposite side of the vehicle
Fig. 41 Grille
Fig. 42 Headlining ± SWB
Fig. 43 Headlining ± LWB
23 - 40 BODYNS
REMOVAL AND INSTALLATION (Continued)

(7) Tighten attaching bolts to 11 to 16 N´m (100 to
140 in. lbs.) torque.
HOOD LATCH STRIKER
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts holding striker to inside of hood
(Fig. 44).
(3) Remove hood latch striker from vehicle.
INSTALLATION
(1) Position hood latch striker on vehicle.
(2) Install bolts to hold hood latch striker to hood.
(3) Align hood latch striker to engage smoothly
into hood latch.
(4) Verify hood operation and alignment. Adjust as
necessary.
(5) Tighten attaching bolts to 11 to 16 N´m (100 to
140 in. lbs.) torque.
HOOD RELEASE CABLE
REMOVAL
(1) Remove hood latch.
(2) Disengage cable end from hood latch locking
mechanism.
(3) Slide cable case end sideways in keyhole slot of
hood latch while pinching barb on cable case closed.
(4) Remove cable from latch (Fig. 47).
(5) Remove hood release handle from instrument
panel.
(6) Disengage rubber grommet cable insulator
from hole in dash panel.
(7) Attach a suitable length of mechanic's wire to
latch end of cable to assist cable installation.
(8) Route cable back from latch through engine
compartment toward dash panel near power brake
booster (Fig. 48).
(9) Remove attaching clips from cable case.
(10) From inside vehicle, pull cable through dash
panel until mechanic's wire is exposed.
(11) Disconnect cable from mechanic's wire.(12) Remove hood release cable from vehicle.
INSTALLATION
(1) Place hood release cable in position under
instrument panel.
(2) Attach latch end of hood release cable to
mechanic's wire protruding through dash panel.
(3) Route cable forward through engine compart-
ment toward latch by pulling on mechanic's wire
(Fig. 48).
(4) Disconnect mechanic's wire from cable.
(5) Engage rubber grommet cable insulator into
hole in dash panel.
(6) Install hood release handle into instrument
panel.
(7) Place cable in position on latch.
(8) Slide cable case end sideways into keyhole slot
of hood latch.
(9) Engage cable end into hood latch locking mech-
anism.
(10) Install hood latch.
(11) Install attaching clips to cable case and install
clips into original holes in strut tower, fender, head-
lamp area, and radiator closure panel crossmember.
HOOD RELEASE HANDLE
REMOVAL
(1) Remove lower steering column cover and knee
blocker reinforcement. Refer to Group 8E, Instru-
ment Panel and Systems for proper procedures.
(2) Remove hood latch cable.
(3) Remove screws holding hood latch release han-
dle to instrument panel brace (Fig. 49).
(4) Remove hood latch release handle from vehicle.
INSTALLATION
(1) Position hood latch release handle on vehicle.
(2) Install screws to hold hood latch release handle
to instrument panel brace.
Fig. 47 Hood Release Cable End Attachment
Fig. 48 Hood Release Cable Routing
23 - 42 BODYNS
REMOVAL AND INSTALLATION (Continued)

(3) Install hood latch cable.
(4) Install lower steering column cover and knee
blocker reinforcement.
JACK STORAGE COVER
LONG WHEEL BASE
REMOVAL
(1) Depress latch handle at top of jack storage
cover (Fig. 50).
(2) Pull outward at top of cover to disengage latch.
(3) Remove jack storage cover from vehicle.
INSTALLATION
(1) Place jack storage cover in position on vehicle.
(2) Align guide pins.
(3) Push inward at top of cover to engage latch
and fastener.
SHORT WHEEL BASE
REMOVAL
(1) Open quarter panel bin storage cover.
(2) Lift upward and rearward on jack storage cover
retaining latch to disengage (Fig. 51).
(3) Remove jack storage cover from vehicle.
INSTALLATION
(1) Position jack storage cover to vehicle.
(2) Snap storage cover latch into position on quar-
ter trim panel.
(3) Close quarter trim panel bin storage cover.
LEFT D-PILLAR TRIM PANEL
REMOVAL
(1) Remove rear header trim cover.
(2) Remove liftgate sill plate.
(3) Remove second rear seat belt turning loop on
long wheel base vehicle.
(4) Remove bolt holding second rear seat belt
lower anchor to quarter on short wheel base vehicle.
(5) Remove jack storage cover.
(6) Remove screws holding trim panel to D-pillar
(Fig. 52), (Fig. 53), and (Fig. 54).
(7) Disengage hidden clips holding trim to D-pillar.
(8) Disconnect speaker wire connector, if equipped.
(9) Pass seat belt through slot in D-pillar trim
panel on short wheel base vehicle.
(10) Remove D-pillar trim from vehicle.
INSTALLATION
(1) Pass seat belt through slot in D-pillar trim
panel on short wheel base vehicle.
(2) Position D-pillar trim panel on vehicle.
Fig. 49 Hood Release Handle
Fig. 50 Jack Storage Cover ± LWB
Fig. 51 Jack Storage Cover ± SWB
NSBODY 23 - 43
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)