2001 CHRYSLER VOYAGER buttons

(10) Install thrust buttons 8491 to both bearing
journals and press halves together using an arbor
press (Fig. 127).
(11) Install ring gear into position, start three ring
gear-to-differential case bolts by hand (120É apart),
and install alignment pins 8470 (Fig. 128).
(12) Torque three ring gear bolts to draw ring gear
into position. Remove alignment pins, install remain-ing ring gear-to-differential case bolts and torque to
95 N´m (70 ft. lbs.) (Fig. 129).
(13) Install tapered roller bearings using installer
8473 and an arbor press (Fig. 130). Insert button
8491 on opposite journal to protect journal and/or
bearing during press operation. Repeat the same
operation on opposite side.
Fig. 125 Side Gear Thrust Washer
1 - SIDE GEAR THRUST WASHER
2 - DIFFERENTIAL SIDE GEAR
Fig. 126 Align Differential Support to Case
1 - ALIGNMENT PIN 8470
2 - DIFFERENTIAL SUPPORT PLATE
3 - DIFFERENTIAL CASE
Fig. 127 Installing Differential Support
1 - ARBOR PRESS
2 - BUTTON 8491
3 - DIFFERENTIAL SUPPORT PLATE
4 - ALIGNMENT PIN 8470
5 - DIFFERENTIAL CASE
Fig. 128 Ring Gear Alignment/Installation
1 - ALIGNMENT PIN 8470
2 - BOLT
RGT850 MANUAL TRANSAXLE21a-49
DIFFERENTIAL (Continued)

MANUAL TEMPERATURE CONTROL
The front blower speed must be set to High and
the evaporator temperature sensor must be greater
than 55É F or the test will fail immediately. The test
is activated by depressing the A/C and PWR buttons
simultaneously and holding them depressed for no
less than five seconds. The PWR and A/C LEDs will
blink on and off until the test is complete. If the
LEDs stop blinking after two minutes, then the cool
down test has been completed successfully. If the two
minutes expire without the evaporator temperature
reaching 20É F less than the outside air temperature,
then the cool down test has been failed and further
A/C system diagnosis is required. If the test is failed,
the LEDs will continue to blink across ignition cycles
until the vehicle has been driven for greater than (3
miles).
AUTOMATIC TEMPERATURE CONTROL
The outside air temperature shown in the ATC dis-
play must not be lower than 53É F or the test will not
begin. The ambient air temperature in the room
where the vehicle will be tested must be a minimum
of 21É C (70ÉF) for this test.The test is activated by
depressing the A/C and PWR buttons simultaneously
and holding them depressed for no less than four sec-
onds. The snowflake icon and the DELAY text in the
ATC display will blink on and off alternately until
the test is complete. If the snowflake icon and the
DELAY text stop blinking after two minutes, then
the cool down test has been completed successfully. If
the two minutes expire without the evaporator tem-
perature reaching 20É F less than the evaporator ini-
tial temperature, then the cool down test has been
failed and further A/C system diagnosis is required.
If the test is failed, the snowflake icon and the
DELAY text will continue to blink across ignition
cycles until the vehicle has been driven for greater
than (3 miles).
DIAGNOSIS AND TESTING - A/C
PERFORMANCE TEST
An air conditioning performance test is the best
way to determine whether the system is performing
up to standard. This test also provides valuable clues
as to the possible cause of trouble with the air con-
ditioning system. The ambient air temperature in the
location where the vehicle will be tested must be a
minimum of 21É C (70ÉF) for this test.
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
NOTE: When connecting the service equipment
coupling to the line fitting, verify that the valve of
the coupling is fully closed. This will reduce the
amount of effort required to make the connection.
(1) Connect a tachometer to monitor the engine
speed.
(2) Remove the caps from the refrigerant system
service ports and attach a manifold gauge set to
monitor the refrigerant system pressures.
(3) Set the heater-air conditioner controls so that
the compressor is engaged, the air within the vehicle
is being recirculated, the output air is directed
through the panel outlets, the temperature control is
in the full cool position, and the blower motor is oper-
ating at its highest speed.
(4) Start the engine and allow the engine to oper-
ate for about five minutes or until it reaches normal
operating temperature. Then hold the engine speed
at 1000 rpm with the compressor clutch engaged. If
the compressor clutch does not engage, proceed with
diagnosis of the compressor clutch coil. (Refer to 24 -
HEATING & AIR CONDITIONING/CONTROLS -
FRONT/COMPRESSOR CLUTCH COIL - DIAGNO-
SIS AND TESTING).
(5) Close all the vehicle windows and doors.
(6) Insert a thermometer in the left center panel
outlet and operate the engine for five minutes.
(7) With the compressor clutch engaged, record the
left center panel outlet discharge air temperature,
the discharge pressure (high side service port), and
the suction pressure (low side service port). The com-
pressor clutch may cycle, depending upon the ambi-
ent temperature and humidity. If the clutch cycles,
use the readings obtained before the clutch disen-
gaged.
(8) Compare the discharge air temperature read-
ing to the Performance Temperature and Pressure
chart. If the temperature reading is high, check the
refrigerant system for leaks and proper refrigerant
charge level. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
DIAGNOSIS AND TESTING - REFRIGERANT SYS-
TEM LEAKS) and (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT/REFRIGER-
ANT - DIAGNOSIS AND TESTING - REFRIGER-
ANT SYSTEM CHARGE LEVEL).
RSHEATING & AIR CONDITIONING24-5
HEATING & AIR CONDITIONING (Continued)

CONTROLS - FRONT
TABLE OF CONTENTS
page page
A/C-HEATER CONTROL
STANDARD PROCEDURE...................8
HEATER-A/C CONTROL CALIBRATION.......8
REMOVAL...............................9
INSTALLATION............................9
A/C PRESSURE TRANSDUCER
DESCRIPTION...........................10
OPERATION.............................10
DIAGNOSIS AND TESTING.................10
A/C PRESSURE TRANSDUCER............10
REMOVAL..............................11
INSTALLATION...........................11
BLEND DOOR ACTUATOR
DESCRIPTION...........................11
OPERATION.............................12
REMOVAL..............................12
INSTALLATION...........................12
BLOWER MOTOR RELAY
DESCRIPTION...........................13
OPERATION.............................14
DIAGNOSIS AND TESTING.................14
BLOWER MOTOR RELAY.................14
REMOVAL..............................14
INSTALLATION...........................14
BLOWER MOTOR RESISTOR
DESCRIPTION...........................15
OPERATION.............................15
DIAGNOSIS AND TESTING.................15
BLOWER MOTOR RESISTOR.............15
REMOVAL..............................16
INSTALLATION...........................16
COMPRESSOR CLUTCH
DESCRIPTION...........................17
OPERATION.............................17
STANDARD PROCEDURE..................18
COMPRESSOR CLUTCH AIR GAP..........18
COMPRESSOR CLUTCH BREAK-IN.........18REMOVAL..............................18
INSPECTION............................19
INSTALLATION...........................20
COMPRESSOR CLUTCH COIL
DIAGNOSIS AND TESTING.................21
COMPRESSOR CLUTCH COIL.............21
COMPRESSOR CLUTCH RELAY
DESCRIPTION...........................21
OPERATION.............................22
DIAGNOSIS AND TESTING.................22
COMPRESSOR CLUTCH RELAY...........22
REMOVAL..............................23
INSTALLATION...........................23
EVAPORATOR TEMPERATURE SENSOR
DESCRIPTION...........................23
OPERATION.............................23
REMOVAL..............................24
INSTALLATION...........................24
INFRARED TEMPERATURE SENSOR
DESCRIPTION...........................24
OPERATION.............................25
MODE DOOR ACTUATOR
DESCRIPTION...........................25
OPERATION.............................25
REMOVAL..............................26
INSTALLATION...........................26
POWER MODULE
DESCRIPTION...........................26
OPERATION.............................27
REMOVAL..............................27
INSTALLATION...........................27
RECIRCULATION DOOR ACTUATOR
DESCRIPTION...........................28
OPERATION.............................28
REMOVAL..............................29
INSTALLATION...........................29
A/C-HEATER CONTROL
STANDARD PROCEDURE - HEATER-A/C
CONTROL CALIBRATION
The heater-A/C control module must be recali-
brated each time an actuator motor or the control
module is replaced. This is necessary so that the con-
trol module can ªlearnº the feedback voltages for
each actuator motor at both stop positions of each
door in the front HVAC unit housing. If the vehicle isso equipped, the calibration procedure also includes
rear HVAC positions for each actuator motor.
(1) Turn the ignition switch to the On position.
(2) Simultaneously depress and hold the Power
and Recirculation buttons on the heater-A/C control
for at least five seconds. The manual heater-A/C con-
trol Delay Light Emitting Diode (LED) and Recircu-
lation LED, or the Automatic Temperature Control
(ATC) heater-A/C control Delay and Recirculation
graphics will begin to flash when the calibration pro-
cedure has begun.
24 - 8 CONTROLS - FRONTRS