1996 CHRYSLER VOYAGER Gear box

boxes behind the front wheels and forward of the
rear wheels inboard of the rocker panel weld seam.
TOWINGÐFRONT WHEEL LIFT
Chrysler Corporation recommends that a vehicle be
towed with the front end lifted, whenever possible. A
90 cm (36 in.) length of 4x4 wood beam can be placed
between the wheel lift device and the bottom of the
fascia to prevent damage to vehicle during the lifting
operation. The beam can removed after lifting the
front of the vehicle.
TOWINGÐREAR WHEEL LIFT
If a vehicle cannot be towed with the front wheels
lifted, the rear wheels can be lifted provided the fol-
lowing guide lines are observed.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
²On AWD vehicles, all four wheels must be free to
rotate. Use towing dollies at unlifted end of vehicle.
²Unlock steering column and secure steering
wheel in straight ahead position with a clamp device
designed for towing.
²3-speed automatic transaxle vehicles can be flat
towed at speeds not to exceed 40 km/h (25 mph) for
not more than 25 km (15 miles). The steering column
must be unlocked and gear selector in neutral.
²4-speed electronic automatic transaxle vehicles
can be flat towed at speeds not to exceed 72 km/h (44
mph) for not more than 160 km (100 miles). The
steering column must be unlocked and gear selector
in neutral.
HOISTING RECOMMENDATIONS
Refer to Owner's Manual provided with vehicle for
proper emergency jacking procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN THE ENGINE OR REAR SUSPENSION
IS REMOVED FROM A VEHICLE, THE CENTER OF
GRAVITY IS ALTERED MAKING SOME HOISTING
CONDITIONS UNSTABLE. PROPERLY SUPPORT ORSECURE VEHICLE TO HOISTING DEVICE WHEN
THESE CONDITIONS EXIST.
CAUTION: Do not position hoisting device on sus-
pension components or front crossmember, dam-
age to vehicle can result.
TO HOIST OR JACK VEHICLE SEE(Fig. 3).
Vehicles with factory installed ground effects are
equipped with front and rear hoisting pads. These
pads are stamped, ªHoist Pointº.
Fig. 3 HOISTING AND JACKING POINTS
NSLUBRICATION AND MAINTENANCE 0 - 9
SERVICE PROCEDURES (Continued)

NS vehicles can be tied to a flat bed device using
the reinforced loops located under the front and rear
bumpers on the drivers side of the vehicle. There are
also four reinforced elongated holes for T or R-hooks
located on the bottom of the front frame rail torque
boxes behind the front wheels and forward of the
rear wheels inboard of the rocker panel weld seam.
TOWINGÐFRONT WHEEL LIFT
Chrysler International recommends that a vehicle
be towed with the front end lifted, whenever possible.
A 90 cm (36 in.) length of 4x4 wood beam can be
placed between the wheel lift device and the bottom
of the fascia to prevent damage to vehicle during the
lifting operation. The beam can removed after lifting
the front of the vehicle.
TOWINGÐREAR WHEEL LIFT
If a vehicle cannot be towed with the front wheels
lifted, the rear wheels can be lifted provided the fol-
lowing guide lines are observed.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
²On AWD vehicles, all four wheels must be free to
rotate. Use towing dollies at unlifted end of vehicle.
²Unlock steering column and secure steering
wheel in straight ahead position with a clamp device
designed for towing.
²4-speed electronic automatic transaxle vehicles
can be flat towed at speeds not to exceed 72 km/h (44
mph) for not more than 160 km (100 miles). The
steering column must be unlocked and gear selector
in neutral.
TOWINGÐTOW HOOKS
WARNING: Do not use the tow hook to lift the vehi-
cle off the ground.
A tow-hook bolt, located in the rear interior trim
storage compartment (with jack), is provided with
your vehicle. The tow hook is used for towing the
vehicle with all four wheels on the ground only. It
can be attached to the vehicle through an opening in
the lower front fascia. The tow hook must be fully
seated to the attach bracket through the lower front
fascia as shown. If the tow hook is not fully seated to
the attach bracket the vehicle should not be towed.
NOTE: The tow hook bolt protective plug must be
removed from the tow hook bracket prior to bolt
attachment. The tow hook is used ONLY for towing
the vehicle with all four wheels on the ground.
Fig. 2
0 - 6 LUBRICATION AND MAINTENANCENS/GS
SERVICE PROCEDURES (Continued)

Upon application of the brake pedal, the lever
should move down, turning the star wheel. A definite
rotation of the star wheel should be seen if the auto-
matic adjuster is working properly. If no rotation of
the star wheel is observed when the pedal is consec-
utively pressed and released, the respective drum
will have to be removed and the adjuster serviced.
MASTER CYLINDER FLUID LEVEL CHECK
The master cylinder used in this vehicle has the
same fluid level markings as the master cylinders
used in other brake systems on the side of the fluid
resevoir. Refer to the Master Cylinder Fluid Level
Check in the Diagnosis and Testing section of group
5 for more information
REMOVAL AND INSTALLATION
FRONT PARK BRAKE CABLE AND LEVER
ASSEMBLY-RHD&LHD VEHICLES
REMOVE
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance group of this service manual.
(2) Remove the intermediate and left rear park
brake cable from the park brake cable equalizer (Fig.
2).
(3) Remove the front park cable housing retainer
from body outrigger bracket (Fig. 3). Cable is remov-
able by sliding a 14 mm box wrench over cable
retainer and compressing the three retaining fingers.
Alternate method is to use an aircraft type hose
clamp and screwdriver.(4) Remove the two (2) retaining nuts and (2)
retaining bolts from the bottom of the parking brake/
gearshift lever bracket.
(5) Lower vehicle.
(6) Carefully lift the base of the gearshift boot
from the gearshift console to access the screws (Fig.
4).
Fig. 2 Park Brake Cable Attachment To Equalizer
Fig. 3 Front Park Brake Cable Attachment To Body
Fig. 4 Console and Gearshift boot
5 - 2 BRAKESNS/GS
DIAGNOSIS AND TESTING (Continued)

(7) Remove the four (4) retaining screws (Fig. 5).
(8) Pull the parking brake lever to the ªupº posi-
tion and lift the console (Fig. 5).
(9) Tilt the base of the gearshift boot and carefully
push through the opening in the console while lifting.
(10) Remove the three (3) nuts at the base of the
parking brake assembly.
(11) Release the parking brake assembly and lift
assembly off of the parking brake/gearshift lever
bracket.
(12) Unhook the loop on the end of the parking
brake from the equalizer bar on the parking brake/
gearshift lever bracket.
(13) Compress the parking brake cable retainer by
sliding a 14 mm box wrench over the cable retainer
and compress the three (3) retaining fingers.
(14) Remove the three (3) screws from the parking
brake grommet on the floor pan of the passenger
compartment.
(15) Lift the parking brake /gearshift lever bracket
and slide the parking brake cable out.
(16) Pull the cable through the floor pan from
inside the vehicle.
INSTALL
(1) Pass park brake cable assembly through hole
in floor pan from the inside of the vehicle.
(2) Pass cable strand button through the hole in
the pedal assembly bracket.
(3) Install parking brake cable to the brake/gear-
shift lever bracket by lifting the bracket and sliding
the cable in.
(4) Install the three (3) screws to the parking
brake grommet on the floor pan of the passenger
compartment.
(5) Compress the parking brake cable retainer by
sliding a 14 mm box wrench over the cable retainer
and compress the three (3) retaining fingers.
(6) Hook the loop on the end of the parking brake
to the equalizer bar on the parking brake/gearshift
lever bracket.
(7) Attach the parking brake assembly and place
assembly on the parking brake/gearshift lever
bracket.
(8) Install the three (3) nuts at the base of the
parking brake assembly.
(9) Pull the parking brake lever to the ªupº posi-
tion.
(10) Place the console over the parking brake/gear-
shift lever and tilt the base of the gearshift boot and
carefully pull it through the opening in the console.
(11) Install the four (4) retaining screws (Fig. 5).
(12) Carefully press the three (3) clips at the base
of the gearshift boot into the slots on the gearshift
console.
(13) Raise the vehicle.
(14) install the two (2) retaining nuts and (2)
retaining bolts to the bottom of the parking brake/
gearshift lever bracket.
(15) Install the front park cable housing retainer
to the body outrigger bracket (Fig. 3). Cable is
installed by sliding a 14 mm box wrench over cable
retainer and compressing the three retaining fingers.
Alternate method is to use an aircraft type hose
clamp and screwdriver.
(16) Install the intermediate and left rear park
brake cable to the park brake cable equalizer (Fig. 2).
(17) Lower the vehicle.
Fig. 5 Console Retaining Screws
NS/GSBRAKES 5 - 3
REMOVAL AND INSTALLATION (Continued)

(8) Using the indicator adjuster thumbwheel on
the indicator clip below the steering column. Rotate
the indicator thumbwheel to position the indicator
calibration arrow to the center of the N slot on the
instrument cluster mask.
(9) After the indicator has been properly adjusted,
move the shift lever through each gear position to
verify the appropriate gear position has been selected
and the slot is fully covered by the indicator. The left
edge of the indicator will just peek at the left edge of
the P slot in Park.
(10) If the indicator is not covering each of the
selected gear positions when selected, place the shift
lever back into neutral N and readjust the indicator.
Repeat the process until each gear is covered when
selected.
(11) Install the metal knee blocker panel.
(12) Install the lower steering column cover.
INSTRUMENT PANEL
The instrument panel is removed as a unit. The
steering column and wiring harnesses are assembled
into the panel before installation. Service procedures
for interior trim not related to the instrument panel
can be found in Group 23, Body.
REMOVAL
(1) Disconnect the battery, negative cable first.
(2) Remove the lower console.
(3) Remove the screw holding the lower heat duct
to the instrument panel support (Fig. 26).
(4) Disconnect the heat duct from the vehicle.
(5) Remove the bolts holding the lower supports to
the instrument panel frame (Fig. 27).(6) Remove the bolts holding the lower supports to
the floor pan.
(7) Remove the right and left end covers.
(8) Disconnect the wire connectors from the Pas-
senger Airbag Module.
(9) Remove the front door sill trim covers.
(10) Remove the A-pillar trim covers.
(11) Remove the glove box.
(12) Disconnect the antenna lead connector from
behind the glove box.
(13) Remove the lower steering column cover.
(14) Remove the knee blocker panel.
(15) Disconnect the lower two, forty pin wire har-
ness connectors, from the main Junction Block near
left cowl side panel (Fig. 28).
(16) Disconnect the instrument panel wire harness
connector from the bottom of Body Control Module.
(17) Disconnect the two forty pin connectors from
the right of the steering column (Fig. 29).
(18) Remove the clinch bolt holding upper the
steering shaft to the lower steering shaft (Fig. 29).
Fig. 25 Range Indicator Cable
Fig. 26 Heat Duct
Fig. 27 Lower Supports
NSINSTRUMENT PANEL AND SYSTEMS 8E - 25
REMOVAL AND INSTALLATION (Continued)

(19) Separate the upper steering shaft from the
lower steering shaft.
(20) Remove the nuts holding the instrument
panel frame to the die-cast brake pedal support on
each side of the steering column.
(21) With mechanical transmission range indica-
tor:
(a) Remove the indicator cable loop.(b) Remove the clip holding gear shift cable end
to the gear selector adapter.
(c) Pull the cable end from gear selector.
(d) Disconnect the clip for the indicator cable
and guide tube from the shift cable bracket and
move out of the way.
(22) Remove the nut holding gear shift cable
bracket to the instrument panel frame.
(23) Remove the bracket from the instrument
panel.
(24) Remove the screw holding hood release handle
to the instrument panel.
(25) Remove the bolt holding the hood release han-
dle to the instrument panel.
(26) Position the hood release handle out of the
way.
(27) Remove the instrument panel top cover.
(28) Disconnect the wire connector from the HVAC
wire harness behind the glove box area.
(29) Remove the bolts holding the instrument
panel frame to the brackets on cowl side panels (Fig.
30) and (Fig. 31).
(30) Loosen, but do not remove, the pivot bolts
holding the instrument panel to the cowl panels.
(31) Remove the bolts holding the instrument
panel frame to the dash panel below windshield
opening.
(32) Remove the instrument panel from vehicle.
INSTALLATION
For installation, reverse the above procedures.
Fig. 28 Junction Block and Body Control Module
Connectors
Fig. 29 40 Way Connectors Location
Fig. 30 Passenger Side Instrument Panel
8E - 26 INSTRUMENT PANEL AND SYSTEMSNS
REMOVAL AND INSTALLATION (Continued)

(6) Remove the bolts holding the lower supports to
the floor pan.
(7) Remove the right and left end covers.
(8) Disconnect the wire connectors from the Pas-
senger Airbag Module.
(9) Remove the front door sill trim covers.
(10) Remove the A-pillar trim covers.
(11) Remove the glove box.
(12) Disconnect the antenna lead connector from
behind the glove box.
(13) Remove the lower steering column cover.
(14) Remove the knee blocker panel.
(15) Disconnect the lower two, forty pin wire har-
ness connectors, from the main Junction Block near
left cowl side panel (Fig. 25).(16) Disconnect the instrument panel wire harness
connector from the bottom of Body Control Module.
(17) Disconnect the two forty pin connectors from
the right of the steering column (Fig. 26).
(18) Remove the clinch bolt holding upper the
steering shaft to the lower steering shaft (Fig. 26).
(19) Separate the upper steering shaft from the
lower steering shaft.
(20) Remove the nuts holding the instrument
panel frame to the die-cast brake pedal support on
each side of the steering column.
(21) With mechanical transmission range indica-
tor:
(a) Remove the indicator cable loop.
(b) Remove the clip holding gear shift cable end
to the gear selector adapter.
(c) Pull the cable end from gear selector.
(d) Disconnect the clip for the indicator cable
and guide tube from the shift cable bracket and
move out of the way.
(22) Remove the nut holding gear shift cable
bracket to the instrument panel frame.
(23) Remove the bracket from the instrument
panel.
(24) Remove the screw holding hood release handle
to the instrument panel.
(25) Remove the bolt holding the hood release han-
dle to the instrument panel.
(26) Position the hood release handle out of the
way.
(27) Remove the instrument panel top cover.
(28) Disconnect the wire connector from the HVAC
wire harness behind the glove box area.
Fig. 24 Lower Supports
Fig. 25 Junction Block and Body Control Module
Connectors
Fig. 26 40 Way Connectors Location
NS/GSINSTRUMENT PANEL AND SYSTEMS 8E - 21
REMOVAL AND INSTALLATION (Continued)

(4) Raise the front wheels off the ground.
(5) Slowly turn the steering wheel right and left,
lightly contacting the wheel stops at least 20 times.
(6) Check the fluid level add if necessary.
(7) Lower the vehicle, start the engine and turn
the steering wheel slowly from lock to lock.
(8) Stop the engine and check the fluid level and
refill as required.
(9) If the fluid is extremely foamy or milky look-
ing, allow the vehicle to stand a few minutes and
repeat the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
REMOVAL AND INSTALLATION
POWER STEERING PUMPÐ2.5L DIESEL
NOTE: The power steering pump is mounted below
the fuel pump on the left side of the engine. The
vehicle should be raised on a hoist to access the
pump from below.
REMOVAL
(1) Remove serpentine drive belt. Refer to Group 7,
Cooling System, for procedure.
(2) Remove power steering pump pulley. Use a hex
wrench to secure the power steering shaft while
removing the pulley bolt with a box wrench. (Fig. 2)
CAUTION: Do not use an impact wrench to remove
the pump pulley ± this can cause rear pump seal
damage. Do not secure power steering shaft with a
wrench on the coupling to the A/C compressor ±
this can cause rear pump seal damage.
(3) Remove coupling bolts (2) from A/C compressor
side of coupling.
(4) Loosen A/C compressor bolts and separate com-
pressor from bracket. Do not disconnect A/C hoses.
(5) Remove bolts (2) securing the power steering
pump to the power steering bracket.
(6) Disconnect power steering pump supply hose at
the pump and drain fluid.
(7) Disconnect power steering pressure hose at the
steering gear assembly.
(8) Remove power steering pump.
INSTALLATION
(1) Install pump on engine.
(2) Tighten pump bracket bolts to 47 N´m (35 ft.
lbs.).(3) Reverse the above procedures in steps 8
through 1 to complete installation.
(4) Add power steering fluid and perform Power
Steering Pump Initial Operation.
Fig. 2 Power Steering Pump Pulley Removal
Fig. 3 Left SIde Motor MountÐVM DIesel
19 - 2 STEERINGNS/GS
SERVICE PROCEDURES (Continued)