2004 CHRYSLER VOYAGER wheel torque

(7) Reduce the inside diameter measurement of
the brake drum that was taken using Special Tool
C-3919 by 1/64 of an inch. Reset Gauge, Brake Shoe,
Special Tool C-3919 or the equivalent used, so that
the outside measurement jaws are set to the reduced
measurement (Fig. 139). (8) Place Gauge, Brake Shoe, Special Tool C-3919,
or equivalent over the park brake shoes. The special
tool must be located diagonally across at the top of
one shoe and bottom of opposite shoe (widest point)
of the park brake shoes. (9) Using the star wheel adjuster, adjust the park
brake shoes until the lining on the park brake shoes
just touches the jaws on the special tool. (10) Repeat step 8 above and measure shoes in
both directions. (11) Install brake rotor on hub and bearing.
(12) Rotate rotor to verify that the park brake
shoes are not dragging on the brake drum. If park
brake shoes are dragging, remove rotor and back off
star wheel adjuster one notch and recheck for brake
shoe drag against drum. Continue with the previous
step until brake shoes are not dragging on brake
drum. (13) Install disc brake caliper on caliper adapter
(Fig. 136). (Refer t o 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DISC BRAKE CALIPERS - INSTALLA-
TION). (14) Install wheel and tire.
(15) Tighten the wheel mounting nuts in the
proper sequence until all nuts are torqued to half the
specified torque. Then repeat the tightening sequence
to the full specified torque of 135 N´m (100 ft. lbs.). (16) Lower vehicle.
(17) Apply and release the park brake pedal one
time. This will seat and correctly adjust the park
brake cables.
CAUTION: Before moving vehicle, pump brake
pedal several times to ensure the vehicle has a firm
enough pedal to stop the vehicle.
(18) Road test the vehicle to ensure proper func-
tion of the vehicle's brake system.
Fig. 137 Measuring Park Brake Drum Diameter
Fig. 138 Reading Park Brake Drum Diameter
1 - SPECIAL TOOL C-3919
2 - RULER
Fig. 139 Setting Gauge To Park Brake Shoe Measurement
1 - RULER
2 - SPECIAL TOOL C-3919
RS BRAKES5s-77
SHOES - PARKING BRAKE (Continued)

DIAGNOSIS AND TESTING - DRIVE PLATE
MISALIGNMENT
Common causes of misalignment are:
²Heat warping
²Mounting drive plate on a dirty crankshaft
flange
²Incorrect bolt tightening
²Improper seating on the crankshaft shoulder
²Loose crankshaft bolts
Clean the crankshaft flange before mounting the
drive plate. Dirt and grease on the flange surface
may misalign the flywheel, causing excessive runout.
Use new bolts when mounting drive plate to crank-
shaft. Tighten drive plate bolts to specified torque
only. Over-tightening can distort the drive plate hub
causing excessive runout.
DIAGNOSIS AND TESTING - CLUTCH COVER
AND DISC RUNOUT
Check condition of the clutch cover before installa-
tion. A warped cover or diaphragm spring will cause
grab and/or incomplete release or engagement. Use
care when handling the clutch assembly. Impact can
distort the cover, diaphragm spring, and release fin-
gers.
DIAGNOSIS AND TESTING - CLUTCH CHATTER
COMPLAINTS
For all clutch chatter complaints, perform the fol-
lowing:
(1) Check for loose, misaligned, or broken engine
and transmission mounts. If present, they should be
corrected at this time. Test vehicle for chatter. If
chatter is gone, there is no need to go any further.
(2) If chatter persists, check hydraulic clutch
release system is functioning properly.
(3) Check for loose connections in drivetrain. Cor-
rect any problems and determine if clutch chatter
complaints have been satisfied. If not:
(a) Remove transaxle.
(b) Check to see if the release bearing is sticky
or binding. Replace bearing, if needed.
(c) Check linkage for excessive wear on the pivot
stud and fork fingers. Replace all worn parts.
(d) Check clutch assembly for contamination
(dirt, oil). Replace clutch assembly, if required.
(e) Check to see if the clutch disc hub splines
are damaged. Replace with new clutch assembly, if
necessary.
(f) Check input shaft splines for damage.
Replace, if necessary.
(g) Check for uneven wear on clutch fingers.
(h) Check for broken clutch cover diaphragm
spring fingers. Replace with new clutch assembly,
if necessary.
SPECIAL TOOLS - T850 TRANSAXLE
CLUTCH RELEASE LEVER AND
BEARING
REMOVAL
(1) Remove transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL -
REMOVAL)
(2) Remove modular clutch assembly from input
shaft (2.4L Gas models only).
(3) Grasp clutch release lever and bearing (Fig. 6)
with both hands and pull outward using moderate
pressure to release lever from pivot ball.
(4) Separate release bearing from lever.
NOTE: Remove release lever pivot ball(s) ONLY if
replacement is necessary.
Disconnect Tool, 6638A
Remover/Installer, 6891
6 - 6 CLUTCHRS
CLUTCH (Continued)

INSTALLATION
(1) Install clutch release bearing and lever (if
removed). (Refer to 6 - CLUTCH/CLUTCH RELEASE
BEARING - INSTALLATION)
(2) Install clutch disc and pressure plate to fly-
wheel (Fig. 21). Install clutch alignment tool, and
install and torque pressure plate-to-flywheel bolts to
28 N´m (250 in. lbs.).
(3)
Install transaxle assembly. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/MANUAL - INSTALLATION)
FLYWHEEL
REMOVAL
(1) Remove transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL -
REMOVAL)
(2) Remove clutch pressure plate and disc. (Refer
to 6 - CLUTCH/CLUTCH DISC - REMOVAL)
(3) Remove flywheel assembly (Fig. 22).
INSTALLATION
(1) Install NEW flywheel-to-crankshaft bolts by
hand.
(2) Torque bolts in a criss-cross sequence to 25
N´m (18 ft. lbs.) (Fig. 22).(3) Torque bolts in a criss-cross sequence an addi-
tional 60É.
(4) Install clutch pressure plate and disc. (Refer to
6 - CLUTCH/CLUTCH DISC - INSTALLATION)
(5) Install transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL - INSTAL-
LATION)
Fig. 21 Clutch Disc and Pressure Plate
1 - FLYWHEEL
2 - DISC
3 - PRESSURE PLATE
Fig. 22 Flywheel Bolt Torque Sequence
6 - 12 CLUTCHRS
CLUTCH DISC AND PRESSURE PLATE - 2.5L TD (Continued)

INSTALLATION
NOTE: If transmission control module is being
replaced with a new or replacement unit, the Pinion
Factor and Quick Learn procedures must be per-
formed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE) (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MODULES/
TRANSMISSION CONTROL MODULE - STANDARD
PROCEDURE)
(1) Install TCM into position (Fig. 20). Install
three (3) screws and torque to 3 N´m (30 in. lbs.).
(2) Install TCM harness 60±way connector (Fig.
21) and torque to 4 N´m (35 in. lbs.).
(3) Install splash shield into position with fasten-
ers.
(4) Install left front wheel/tire assembly.
(5) Lower vehicle.
(6) Connect battery negative cable.
(7) If TCM was replaced, reset Pinion Factor and
Quick Learn. (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)(Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE).
Fig. 19 Transmission Control Module Removal/
Installation
1 - SCREW
2 - TRANSMISSION CONTROL MODULE (TCM)
3 - CLIP
4 - LEFT RAIL
Fig. 20 Transmission Control Module Removal/
Installation
1 - SCREW
2 - TRANSMISSION CONTROL MODULE (TCM)
3 - CLIP
4 - LEFT RAIL
Fig. 21 Transmission Control Module 60-way
Connector
1 - TRANSMISSION CONTROL MODULE (TCM)
2 - 60-WAY CONNECTOR
8E - 24 ELECTRONIC CONTROL MODULESRS
TRANSMISSION CONTROL MODULE (Continued)

STARTING
TABLE OF CONTENTS
page page
STARTING
DESCRIPTION.........................28
OPERATION...........................28
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - STARTING
SYSTEM TEST.......................28
DIAGNOSIS AND TESTING - CONTROL
CIRCUIT TEST........................30
DIAGNOSIS AND TESTING - FEED CIRCUIT
RESISTANCE TEST....................32
DIAGNOSIS AND TESTING - FEED CIRCUIT
TEST...............................33SPECIFICATIONS
Torques.............................33
STARTER ...........................34
STARTER MOTOR
REMOVAL
REMOVAL - 2.4L......................34
REMOVAL - 3.3/3.8L...................35
INSTALLATION
INSTALLATION - 2.4L..................35
INSTALLATION - 3.3/3.8L................36
STARTING
DESCRIPTION
The starting system consists of:
²Starter relay
²Starter motor (including an integral starter sole-
noid)
Other components to be considered as part of start-
ing system are:
²Battery
²Battery cables
²Ignition switch and key lock cylinder
²Clutch pedal position switch (manual transmis-
sion)
²Park/neutral position switch (automatic trans-
mission)
²Wire harnesses and connections.
The Battery, Starting, and Charging systems oper-
ate in conjunction with one another, and must be
tested as a complete system. For correct operation of
starting/charging systems, all components used in
these 3 systems must perform within specifications.
When attempting to diagnose any of these systems, it
is important that you keep their interdependency in
mind.
The diagnostic procedures used in each of these
groups include the most basic conventional diagnostic
methods, to the more sophisticated On-Board Diag-
nostics (OBD) built into the Powertrain Control Mod-
ule (PCM). Use of an induction-type milliampere
ammeter, volt/ohmmeter, battery charger, carbon pile
rheostat (load tester), and 12-volt test lamp may be
required.
OPERATION
These components form two separate circuits. A
high amperage circuit that feeds the starter motor up
to 300+ amps, and a control circuit that operates on
less than 20 amps.
The PCM controls a double start over-ride safety
that does not allow the starter to be engaged if the
engine is already running.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - STARTING
SYSTEM TEST
For circuit descriptions and diagrams, refer to the
Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO THE PASSIVE RESTRAINT SYS-
TEMS BEFORE ATTEMPTING STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
INSPECTION
Before removing any unit from the starting system
for repair or diagnosis, perform the following inspec-
tions:
²Battery- Visually inspect the battery for indi-
cations of physical damage and loose or corroded
cable connections. Determine the state-of-charge and
cranking capacity of the battery. Charge or replace
8F - 28 STARTINGRS

CONDITION POSSIBLE CAUSE CORRECTION
2. STARTING CIRCUIT
WIRING FAULTY.2. REFER TO THE FEED CIRCUIT RESISTANCE TEST AND
THE FEED CIRCUIT TEST IN THIS SECTION. REPAIR AS
NECESSARY.
3. STARTER ASSEMBLY
FAULTY.3. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
4. ENGINE SEIZED. 4. REFER TO THE ENGINE SECTION, FOR DIAGNOSTIC AND
SERVICE PROCEDURES.
5. LOOSE
CONNECTION AT
BATTERY, PDC,
STARTER, OR ENGINE
GROUND.5. INSPECT FOR LOOSE CONNECTIONS.
6. FAULTY TEETH ON
RING GEAR.6. ROTATE FLYWHEEL 360É, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
STARTER
ENGAGES,
SPINS OUT
BEFORE
ENGINE
STARTS.1. BROKEN TEETH ON
STARTER RING GEAR.1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE
IF NECESSARY.
2. STARTER ASSEMBLY
FAULTY.2. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
STARTER DOES
NOT
DISENGAGE.1. STARTER
IMPROPERLY
INSTALLED.1. INSTALL STARTER. TIGHTEN STARTER MOUNTING
HARDWARE TO CORRECT TORQUE SPECIFICATIONS.
2. STARTER RELAY
FAULTY.2. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.
3. IGNITION SWITCH
FAULTY.3. REFER TO IGNITION SWITCH TEST, IN THE STEERING
SECTION. REPLACE SWITCH, IF NECESSARY.
4. STARTER ASSEMBLY
FAULTY.4. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
5. FAULTY TEETH ON
RING GEAR.5. ROTATE FLYWHEEL 360É, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
DIAGNOSIS AND TESTING - CONTROL
CIRCUIT TEST
The starter control circuit has:
²Starter motor with integral solenoid
²Starter relay
²Transmission range sensor, or Park/Neutral
Position switch with automatic transmissions
²Ignition switch
²Battery
²All related wiring and connections
²Powertrain Control Module (PCM)
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.²To disable ignition and fuel systems, disconnect
the Automatic Shutdown Relay (ASD). The ASD relay
is located in the Power Distribution Center (PDC).
Refer to the PDC cover for the proper relay location.
STARTER SOLENOID
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK POSITION WITH THE
PARKING BRAKE APPLIED.
(1) Verify battery condition. Battery must be in
good condition with a full charge before performing
any starter tests. Refer to Battery Tests.
(2) Perform Starter Solenoid test BEFORE per-
forming the starter relay test.
8F - 30 STARTINGRS
STARTING (Continued)

STARTING
TABLE OF CONTENTS
page page
STARTING DESCRIPTION .........................30
OPERATION ...........................30
DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - STARTINGSYSTEM TEST .......................30
DIAGNOSIS AND TESTING - CONTROL CIRCUIT TEST ........................32
DIAGNOSIS AND TESTING - FEED CIRCUIT RESISTANCE TEST ....................34
DIAGNOSIS AND TESTING - FEED CIRCUIT TEST ...............................35 SPECIFICATIONS
Torques .............................35
STARTER ...........................36
STARTER MOTOR REMOVAL REMOVAL - 2.4L ......................36
REMOVAL - 3.3/3.8L ...................36
REMOVAL - 2.5L ......................36
INSTALLATION INSTALLATION - 2.4L ..................37
INSTALLATION - 3.3/3.8L ................37
INSTALLATION - 2.5L ..................38
STARTING
DESCRIPTION
The starting system consists of:
²Starter relay
² Starter motor (including an integral starter sole-
noid) Other components to be considered as part of start-
ing system are: ² Battery
² Battery cables
² Ignition switch and key lock cylinder
² Clutch pedal position switch (manual transmis-
sion) ² Park/neutral position switch (automatic trans-
mission) ² Wire harnesses and connections.
The Battery, Starting, and Charging systems oper-
ate in conjunction with one another, and must be
tested as a complete system. For correct operation of
starting/charging systems, all components used in
these 3 systems must perform within specifications.
When attempting to diagnose any of these systems, it
is important that you keep their interdependency in
mind. The diagnostic procedures used in each of these
groups include the most basic conventional diagnostic
methods, to the more sophisticated On-Board Diag-
nostics (OBD) built into the Powertrain Control Mod-
ule (PCM). Use of an induction-type milliampere
ammeter, volt/ohmmeter, battery charger, carbon pile
rheostat (load tester), and 12-volt test lamp may be
required.
OPERATION
These components form two separate circuits. A
high amperage circuit that feeds the starter motor up
to 300+ amps, and a control circuit that operates on
less than 20 amps. The PCM controls a double start over-ride safety
that does not allow the starter to be engaged if the
engine is already running.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - STARTING
SYSTEM TEST
For circuit descriptions and diagrams, refer to the
Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO THE PASSIVE RESTRAINT SYS-
TEMS BEFORE ATTEMPTING STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
INSPECTION
Before removing any unit from the starting system
for repair or diagnosis, perform the following inspec-
tions: ² Battery - Visually inspect the battery for indi-
cations of physical damage and loose or corroded
cable connections. Determine the state-of-charge and
cranking capacity of the battery. Charge or replace
8Fs - 30 STARTINGRS

CONDITION POSSIBLE CAUSE CORRECTION2. STARTING CIRCUIT
WIRING FAULTY. 2. REFER TO THE FEED CIRCUIT RESISTANCE TEST AND
THE FEED CIRCUIT TEST IN THIS SECTION. REPAIR AS
NECESSARY.
3. STARTER ASSEMBLY
FAULTY. 3. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
4. ENGINE SEIZED. 4. REFER TO THE ENGINE SECTION, FOR DIAGNOSTIC AND SERVICE PROCEDURES.
5. LOOSE
CONNECTION AT
BATTERY, PDC,
STARTER, OR ENGINE
GROUND. 5. INSPECT FOR LOOSE CONNECTIONS.
6. FAULTY TEETH ON
RING GEAR. 6. ROTATE FLYWHEEL 360É, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
STARTER
ENGAGES,
SPINS OUT
BEFORE
ENGINE
STARTS. 1. BROKEN TEETH ON
STARTER RING GEAR.
1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE
IF NECESSARY.
2. STARTER ASSEMBLY
FAULTY. 2. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
STARTER DOES
NOT
DISENGAGE. 1. STARTER
IMPROPERLY
INSTALLED. 1. INSTALL STARTER. TIGHTEN STARTER MOUNTING
HARDWARE TO CORRECT TORQUE SPECIFICATIONS.
2. STARTER RELAY
FAULTY. 2. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.
3. IGNITION SWITCH
FAULTY. 3. REFER TO IGNITION SWITCH TEST, IN THE STEERING
SECTION. REPLACE SWITCH, IF NECESSARY.
4. STARTER ASSEMBLY
FAULTY. 4. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
5. FAULTY TEETH ON
RING GEAR. 5. ROTATE FLYWHEEL 360É, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
DIAGNOSIS AND TESTING - CONTROL
CIRCUIT TEST
The starter control circuit has:
²
Starter motor with integral solenoid
² Starter relay
² Transmission range sensor, or Park/Neutral
Position switch with automatic transmissions ² Ignition switch
² Battery
² All related wiring and connections
² Powertrain Control Module (PCM)
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled. ²
To disable ignition and fuel systems, disconnect
the Automatic Shutdown Relay (ASD). The ASD relay
is located in the Power Distribution Center (PDC).
Refer to the PDC cover for the proper relay location.
STARTER SOLENOID
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK POSITION WITH THE
PARKING BRAKE APPLIED. THIS MAY RESULT IN
PERSONAL INJURY OR DEATH.
(1) Verify battery condition. Battery must be in
good condition with a full charge before performing
any starter tests. Refer to Battery Tests.
8Fs - 32 STARTINGRS
STARTING (Continued)