2001 CHRYSLER VOYAGER warning

TABLE OF CONTENTS
1.0 INTRODUCTION.........................................................1
1.1SYSTEM COVERAGE...............................................1
1.2SIX -STEP TROUBLESHOOTING PROCEDURE..........................1
2.0 IDENTIFICATION OF SYSTEM.............................................1
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION......................1
3.1GENERAL DESCRIPTION............................................1
3.2FUNCTIONAL OPERATION...........................................1
3.2.1AUTOSTICK FEATURE.......................................1
3.2.2TRANSMISSION OPERATION AND SHIFT SCHEDULING AT
VARIOUS OIL TEMPERATURES................................2
3.3DIAGNOSTIC TROUBLE CODES......................................3
3.3.1HARD CODE................................................3
3.3.2ONE TRIP FAILURES.........................................3
3.3.3INTERMITTENT CODE........................................3
3.3.4STARTS SINCE SET COUNTER................................3
3.3.5TROUBLE CODE ERASURE...................................4
3.3.6LIST OF DIAGNOSTIC TROUBLE CODES........................4
3.3.7DTC DESCRIPTIONS.........................................5
3.3.8QUICK LEARN.............................................16
3.3.9CLUTCH VOLUMES.........................................17
3.3.10ELECTRONIC PINION FACTOR...............................17
3.4USING THE DRBIIIT................................................18
3.5DRBIIITERROR MESSAGES........................................18
3.5.1DRBIIITDOES NOT POWER UP (BLANK SCREEN)...............18
3.5.2DISPLAY IS NOT VISIBLE....................................18
3.6TRANSMISSION SIMULATOR (MILLER TOOL # 8333) AND
FWD ADAPTER (MILLER TOOL #8333-1)..............................18
4.0 DISCLAIMERS, SAFETY, AND WARNINGS.................................18
4.1DISCLAIMERS.....................................................18
4.2.1TECHNICIAN SAFETY INFORMATION..........................19
4.2.2VEHICLE PREPARATION FOR TESTING........................19
4.2.3SERVICING SUB-ASSEMBLIES...............................19
4.2.4DRBIIITSAFETY INSTRUCTIONS.............................19
4.3WARNINGS.......................................................20
4.3.1VEHICLE DAMAGE WARNINGS...............................20
4.3.2ROAD TEST COMPLAINT VEHICLE............................20
4.3.3ELECTRONIC PINION FACTOR WARNINGS.....................20
4.3.4BULLETINS AND RECALLS...................................20
5.0 REQUIRED TOOLS AND EQUIPMENT.....................................20
6.0 GLOSSARY OF TERMS..................................................21
6.1ACRONYMS......................................................21
6.2DEFINITIONS.....................................................21
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES...........................23
i

3.4 USING THE DRBIIIT
Refer to the DRBIIItusers guide for instructions
and assistance with reading trouble codes, erasing
trouble codes, and other DRBIIItfunctions.
3.5 DRBIIITERROR MESSAGES
Under normal operation, the DRBIIItwill dis-
play one of only two error messages:
± User-Requested WARM Boot
± User-Requested COLD Boot
If the DRBIIItshould display any other error
message, record the entire display and call the
S.T.A.R.. Center. This is a sample of such an error
message display:
ver: 2.14
date: 26 Jul93
file: key_itf.cc
date: Jul 26 1993
line: 548
err: 0x1
User-Requested COLD Boot
Press MORE to switch between this
display and the application screen.
Press F4 when done noting information.
3.5.1 DRBIIITDOES NOT POWER UP
(BLANK SCREEN)
If the LED's do not light or no sound is emitted at
start up, check for loose cable connections or a bad
cable. Check the vehicle battery voltage. A mini-
mum of 11 volts is required to adequately power the
DRBIIIt.
If all connections are proper between the DRBIIIt
and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRBIIIt
may be the result of faulty cable or vehicle wiring.
For a blank screen, refer to the appropriate Body
Diagnostic manual.
3.5.2 DISPLAY IS NOT VISIBLE
Low temperatures will affect the visibility of the
display. Adjust the contrast to compensate for this
condition.
3.6 TRANSMISSION SIMULATOR
(MILLER TOOL # 8333) AND FWD
ADAPTER (MILLER TOOL #8333-1)
The transmission simulator, simply put, is an
electronic device that simulates the electronic func-
tions of any EATX controlled transmission (41TE,
42LE, 45RFE, and 545RFE). It's basic function is toaid the technician in determining if an internal
transmission problem exists or if the problem re-
sides in the vehicle wiring or Transmission Control
Module (TCM). It is only useful for electrical prob-
lems. It will not aid in the diagnosis of a failed
mechanical component, but it can tell you that the
TCM and wiring are working properly and that the
problem is internal.
The ignition switch should be in the lock position
before attempting to install the simulator. Follow
all instructions included with the simulator. If the
feedback from the simulator is in doubt, you can
verify it's operation by installing it on a known good
vehicle. A9known good vehicle9would be defined as
a vehicle that does not set any DTC's and drives and
shifts as expected.
One important point to remember is that the
Simulator receives it's power from the Trans Relay
Output circuit. If the transmission system is in
Limp-in (Relay open), the simulator will not oper-
ate. This is not really an indication of a problem,
but an additional symptom. If the simulator does
not power up (9P9led lit), this is an indication that
the problem is still present with the simulator
hooked up. This indicates that the problem is in the
wiring or TCM and not the transmission.
Miller Tool # 8333-1 consists of the adapter cables
and overlay necessary to adapt the simulator to
41TE and 42LE transmissions.
4.0 DISCLAIMERS, SAFETY,
AND WARNINGS
4.1 DISCLAIMERS
All information, illustrations and specifications
contained in this manual are based on the latest
18
GENERAL INFORMATION

information at the time of publication. The right is
reserved to make changes at any time without
notice.
4.2.1 TECHNICIAN SAFETY INFORMATION
WARNING: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
SLOWER REACTION TIMES AND CAN LEAD
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING, KEEP SERVICE AREAS WELL
VENTILATED OR ATTACH THE VEHICLE
EXHAUST SYSTEM TO THE SHOP EXHAUST
REMOVAL SYSTEM.
Some operations in this manual require that
hydraulic tubes, hoses, and fittings, disconnected
for inspection or testing purposes. These systems,
when fully charged contains fluid at high pressure.
Before disconnecting any hydraulic tubes, hoses or
fittings, be sure that the system is fully depressur-
ized.
When servicing a vehicle, always wear eye pro-
tection and remove any metal jewelry such as
watchbands or bracelets that might make an inad-
vertent electrical contact.
When diagnosing a transmission system problem,
it is important to follow approved procedures where
applicable. Following these procedures is very im-
portant to the safety of individuals performing
diagnostic tests.
4.2.2 VEHICLE PREPARATION FOR
TESTING
Make sure the vehicle being tested has a fully
charged battery. If it does not, false diagnostic codes
or error messages may occur. It is extremely impor-
tant that accurate shift lever position data be avail-
able to the TCM. The accuracy of any diagnostic
trouble code found in memory is doubtful unless the
Shift Lever Test, performed on the DRBtScan Tool,
passes.
4.2.3 SERVICING SUB-ASSEMBLIES
Some components of the powertrain system are
intended to be serviced in assembly only. Attempt-
ing to remove or repair certain system subcompo-
nents may result in personal injury and/or im-
proper system operation. Only those components
with approved repair and installation procedures in
the service instructions should be serviced.
4.2.4 DRBIIITSAFETY INSTRUCTIONS
WARNING: EXCEEDING THE LIMITS OF THE
DRBTMULTIMETER IS DANGEROUS. IT CAN
EXPOSE YOU TO SERIOUS OR POSSIBLY
FATAL INJURY. CAREFULLY READ AND
UNDERSTAND THE CAUTIONS AND THE
SPECIFICATION LIMITS.
²Follow the vehicle manufacturer 's service speci-
fications at all times.
²Do not use the DRBtif it has been damaged.
²Do not use the test leads if the insulation is
damaged or if metal is exposed.
²To avoid electrical shock, do not touch the test
leads, tips, or the circuit being tested.
²Choose the proper range and function for the
measurement. Do not try voltage or current mea-
surements that may exceed the rated capacity.
²Do not exceed the limits shown in the table.
FUNCTION INPUT LIMIT
Volts 0 - 500 peak volts AC
0 - 500 volts DC
Ohms (resistance)* 0 - 1.12 megohms
Frequency Measured
Frequency Generated0-10kHz
Temperature -58 - 1100ÉF
-50 - 600ÉC
*Ohms cannot be measured if voltage is present.
Ohms can be measured only in a non-powered
circuit.
²Voltage between any terminal and ground must
not exceed 500v peak AC.
²Use caution when measuring voltage above 25v
DC or 25v AC.
²The circuit being tested must be protected by a
10A fuse or circuit breaker.
²Use the low current shunt to measure circuits up
to 10A. Use the high current clamp to measure
circuits exceeds 10A.
²When testing for the presence of voltage or cur-
rent, make sure the meter is functioning cor-
rectly. Take a reading of a known voltage or
current before attempting a zero reading.
²When measuring current, connect the meter in
series with the load.
²Disconnect the live test lead before disconnecting
the common test lead.
²When using the meter function, keep the DRBt
away from spark plug or coil wires to avoid
measuring error from outside interference.
19
GENERAL INFORMATION

4.3 WARNINGS
4.3.1 VEHICLE DAMAGE WARNINGS
Before disconnecting any control module, make
sure the ignition is ªoffº. Failure to do so could
damage the module.
When testing voltage or continuity at any control
module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the
insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as
to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a
second code could be set, making diagnosis of the
original problem more difficult.
4.3.2 ROAD TEST COMPLAINT VEHICLE
Some complaints will require a test drive as part
of the repair verification procedure. The purpose of
the test drive is to try to duplicate the diagnostic
code or symptom condition.
CAUTION: BEFORE ROAD TESTING A
VEHICLE, BE SURE THAT ALL
COMPONENTS ARE REASSEMBLED.
DURING THE TEST DRIVE, DO NOT TRY TO
READ THE DRBIIITSCREEN WHILE IN
MOTION. DO NOT HANG THE DRBIIITFROM
THE REAR VIEW MIRROR OR OPERATE IT
YOURSELF. HAVE AN ASSISTANT
AVAILABLE TO OPERATE THE DRBIIIT.
Road testing is an essential step in the diagnostic
process that must not be overlooked. Along with
diagnostic information obtained from the DRBIIIt
Scan Tool and the original customer concern, the
road test helps to verify the problem and observe
operation under actual vehicle driving conditions.
Just as important as the road test is, there are
preliminary inspections that should be carried out
prior to the road test. Always check the fluid level
and condition before going on a road test or per-
forming other tests. Also try to determine the type
of fluid being used. Improper fluid can result in
problems. Additionally, a variety of complaints can
be caused by incorrect fluid level. Some of the
conditions caused by incorrect fluid level are as
follows:
²Delayed engagement
²Poor shifting or erratic shifts
²Excessive noise
²Overheating
The next step is to verify that the shift linkage is
correctly adjusted. If the gearshift linkage is incor-rectly adjusted because of wear or incorrect adjust-
ment, a number of complaints can result.
The TCM monitors the Shift Lever Position (SLP)
Sensor at all times. If the linkage is incorrectly
adjusted, the TCM may sense a shift lever position
that is not correct for the gear range chosen by the
driver. This may cause diagnostic trouble codes to
be set and a possible limp-in situation.
The following complaints may also be the result
of an incorrectly adjusted or worn linkage.
²Delayed clutch engagement or erratic shifts
²Vehicle able to drive in Neutral
²Engine not able to crank in Park or Neutral
²Gearshift linkage able to be shifted without the
key in the ignition
²Not able to remove the ignition key in Reverse
²Parking pawl not engaging
The shift linkage should also be adjusted when
replacing the transaxle, repairing the valve body or
repairing any component between the shift lever
and the transaxle.
Some questions to ask yourself when considering
the road test are listed below:
²Is the complaint or concern what you think it is,
based the driver 's description of the problem?
²Is the transaxle operating normally, or is there a
real problem?
²When does the malfunction occur?
²Is the problem in only one gear range?
²What temperature does the complaint occur?
²Is the transaxle in limp-in mode?
4.3.3 ELECTRONIC PINION FACTOR
WARNINGS
The pinion factor must be set for all new trans-
mission control modules. If the pinion factor is not
set or if it is set incorrectly, any speedometer, speed
control, rolling door locks, and other devices that
are operated by the powertrain and body controllers
will not function properly.
4.3.4 BULLETINS AND RECALLS
The service procedures contained in this manual
are correct. provided that all applicable Safety
Recalls and Technical Service Bulletins have been
performed.
5.0 REQUIRED TOOLS AND
EQUIPMENT
> DRBIIIt(diagnostic read-out box) - Must be at
latest release level.
20
GENERAL INFORMATION

TEST ACTION APPLICABILITY
2 Start the engine in park.
Raise the drive wheels off of the ground.
WARNING: PROPERLY SUPPORT THE VEHICLE.
Place transmission in drive, release foot from brake.
WARNING: BE SURE TO KEEP HANDS AND FEET CLEAR OF ROTATING
WHEELS.
Note: The drive wheels must be turning at this point.
With the DRBIIIt, observe the Output RPM
Is the Output RPM below 100?All
Ye s®Go To 3
No®Go To 11
3 Turn the ignition off to the lock position.
CAUTION: Remove the Starter Relay from the IPM. This will prevent the
vehicle from being started in gear.
Install Transmission Simulator, Miller tool #8333 and the FWD Adapter Cable kit,
Miller tool #8333-1.
Ignition on, engine not running.
Using the Transmission Simulator, set the rotary knob to the 3000/1250 position.
Turn the9Input/Output9switch to ON.
With the DRBIIIt, read the Input RPM and Output RPM.
Does the Input RPM read 3000 and the Output RPM read 1250 +/-50 RPM?All
Ye s®Go To 4
No®Go To 5
4 If there are no possible causes remaining, view repair. All
Repair
Replace the Output Speed Sensor.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
5 Turn the ignition off to the lock position.
Disconnect the TCM harness connector.
Disconnect the Output Speed Sensor harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of the Output Speed Sensor Signal circuit from the TCM
harness connector to the Output Speed Sensor harness connector.
Is the resistance above 5.0 ohms?All
Ye s®Repair the Output Speed Sensor Signal circuit for an open.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
No®Go To 6
6 Turn the ignition off to the lock position.
Disconnect the TCM harness connector.
Disconnect the Output Speed Sensor harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of the Speed Sensor Ground circuit from the TCM harness
connector to the Output Speed Sensor harness connector.
Is the resistance above 5.0 ohms?All
Ye s®Repair the Speed Sensor Ground circuit for an open.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
No®Go To 7
43
TRANSMISSION
P0720-OUTPUT SPEED SENSOR ERROR ÐContinued

Symptom:
*TRANSMISSION NOISY WITH NO DTC'S PRESENT
POSSIBLE CAUSES
INCORRECT FLUID LEVEL
INTERNAL TRANSMISSION PROBLEM - NOISY
INTERNAL TRANSMISSION PROBLEM - NOISY WHILE STANDING STILL
TEST ACTION APPLICABILITY
1 Check the Transmission Fluid Level per the Service Information.
Is the fluid level OK?All
Ye s®Go To 2
No®Adjust fluid level and repair cause of incorrect fluid level.
2 Place vehicle on hoist.
WARNING: BE SURE TO KEEP HANDS AND FEET CLEAR OF ROTATING
WHEELS.
Run vehicle on hoist under conditions necessary to duplicate the noise.
NOTE: It may be necessary to test drive the vehicle to duplicate the noise.
Using Chassis Ears or other suitable listening device, verify the source of the noise.
Is the noise coming from the transmission?All
Ye s®Go To 3
No®Test Complete.
3 With the shift lever in neutral, raise the engine speed and listen to the noise.
NOTE: THE RADIO MUST BE TURNED OFF. Alternator noise can come
through the speakers and be misinterpreted as Transmission Pump Whine.
This can happen even with the volume turned down.
Does the noise get louder or change pitch while the engine speed is changing?All
Ye s®Go To 4
No®Go To 5
4 If there are no possible causes remaining, view repair. All
Repair
Repair internal transmission problem as necessary. Inspect all of
the transmission components for signs of wear. If no problems
found, replace the Transmission oil pump..
5 If there are no possible causes remaining, view repair. All
Repair
Repair internal transmission problem as necessary. Inspect all of
the transmission components for signs of wear. Pay particular
attention to bearings, pinion gears, etc. Repair or replace as
necessary.
154
TRANSMISSION