2004 CHRYSLER VOYAGER service

(4) Install low/reverse piston retainer-to-case bolts
(Fig. 74) and torque to 5 N´m (45 in. lbs.).
NOTE: The Low/Reverse Clutch Piston has bonded
seals which are not individually serviceable. Seal
replacement requires replacement of the piston
assembly.
(5) Install low/reverse clutch piston (Fig. 75). (6) Assemble park guide bracket assembly (Fig.
77) (Fig. 76).
Fig. 74 Install Piston Retainer Attaching Screws
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - SCREWDRIVER
3 - TORX-LOC SCREWS
Fig. 75 Install Low/Reverse Clutch Piston
1 - LOW/REVERSE CLUTCH PISTON
2 - BONDED SEAL
3 - BONDED SEAL
Fig. 76 Guide Bracket Disassembled
1 - ANTIRATCHET SPRING
2 - GUIDE BRACKET
3 - SPLIT SLEEVE
4 - SPACER
5-PAWL
6 - STEPPED SPACER
Fig. 77 Guide Bracket
1 - GUIDE BRACKET
2 - ANTIRATCHET SPRING (MUST BE ASSEMBLED AS SHOWN)
3-PAWL
RS 41TE AUTOMATIC TRANSAXLE21s - 185
41TE AUTOMATIC TRANSAXLE (Continued)

(42) Install tapered snap ring (with tapered side
up) as shown in (Fig. 113) (Fig. 114).
(43) Set up dial indicator as shown in (Fig. 115) to
measure low/reverse clutch clearance. Press down on
clutch pack with finger and zero dial indicator. Low/
Reverse clutch pack clearance is 0.89-1.47 mm
(0.035-0.058 in.) . Set up indicator and record mea-
surement in four (4) places. Take average of readings
and select the proper low/reverse reaction plate to
achieve specifications.
LOW/REVERSE REACTION PLATE CHART
PART NUMBER THICKNESS
4799846AA 5.88 mm (0.232 in.)
4799847AA 6.14 mm (0.242 in.)
4799848AA 6.40 mm (0.252 in.)
4799849AA 6.66 mm (0.262 in.)
4799855AA 6.92 mm (0.273 in.)
(44) Install 2/4 clutch pack (Fig. 116).
NOTE: The 2/4 Clutch Piston has bonded seals
which are not individually serviceable. Seal replace-
ment requires replacement of the piston assembly.
Fig. 113 Tapered Snap Ring Instructions
Fig. 114 Snap Ring Installed
1 - SCREWDRIVER
2 - TAPERED SNAP RING (INSTALL AS SHOWN)
Fig. 115 Check Low/Reverse Clutch Clearance
1 - DIAL INDICATOR
2 - DIAL INDICATOR TIP TOOL 6268
3 - HOOK TOOL
Fig. 116 Install 2/4 Clutch Pack
1 - CLUTCH PLATE (4)
2 - CLUTCH DISC (4)
21s - 198 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)

If a road tire is replaced by the spare, the TPM
system will detect the swap and the message9SPARE
TIRE IN USE? Y/N9(along with a chime) will be dis-
played.
For further information, refer to the Owners Man-
ual or the Appropriate Diagnostic Information.
TPM THRESHOLD PRESSURES
High Pressure ON Threshold 48 PSI (331 kPa)
High Pressure OFF Threshold 43 PSI (296 kPa)
Placard Pressure (Cold) 36 PSI (248 kPa)
Low Pressure OFF Threshold 33 PSI (228 kPa)
Low Pressure ON Threshold 28 PSI (193 kPa)
SENSOR - TPM
DESCRIPTION
On vehicles equipped with Tire Pressure Monitor-
ing, one tire pressure sensor is mounted to each
wheel (Fig. 19). Each sensor has an internal battery
that lasts up to 10 years. The battery is not service-
able. At the time of battery failure, the sensor must
be replaced. The serviceable components of the tire
pressure sensor are:
²Sensor-To-Wheel Grommet
²Valve Stem Cap
²Valve Stem Core
Valve stem caps and cores are specifically designed
for the tire pressure monitoring sensors. Although
similar to standard valve stem caps and cores, they
are different.
CAUTION: Do not use a standard valve stem cap or
core in a tire pressure sensor. Always use the orig-
inal equipment style sensor cap and core.
CAUTION: Do not reuse the Sensor-To Wheel Grom-
met. Always use a new grommet when installing a
pressure sensor and properly torque the sensor
nut.
CAUTION: Do not try to install a tire pressure sen-
sor in a steel wheel or aftermarket wheel. Use only
in original style factory wheels.
OPERATION
Tire pressure sensors are battery operated. They
transmit tire pressure data once every minute at
speeds above 20 mph (32 km/h) or up to once every
hour when stationary (parked). For additional infor-
mation, refer to Appropriate Diagnostic Information.
CAUTION
CAUTION: The use of tire sealants is strictly prohib-
ited for vehicles equipped with the Tire Pressure
Monitoring system. Tire sealants can clog tire pres-
sure sensors.
CAUTION: Tire pressure sensor valve stem caps
and cores are specially designed for the sensors.
Due to risk of corrosion, do not use a standard
valve stem cap or core in a tire pressure sensor in
place of the original equipment style sensor cap
and core.
CAUTION: Do not attempt to install a tire pressure
sensor in a steel wheel or aftermarket wheel. Use
tire pressure sensors in original style factory
wheels only.
NOTE: TPM thresholds have been established for
the original tire size equipped on the vehicle. Use
original size tires only to maintain system accuracy.
DIAGNOSIS AND TESTING - TIRE PRESSURE
SENSOR
NOTE: Tire pressure may increase from 2 to 6 psi
(14 to 41 kPa) during normal driving conditions. Do
NOT reduce this normal pressure build up.
If a fault in the system is detected, always check
air pressure in the tires first with a known accurate
air gauge and correct the inflation pressure. If any
tire is low, inspectalltires.
If gauge-read pressure in the tires does not reflect
the reading on the EVIC, retrain the sensors, then
reevaluate (Refer to 22 - TIRES/WHEELS/TIRE
PRESSURE MONITORING/SENSOR - STANDARD
PROCEDURE). Refer to the appropriate diagnostic
information for complete diagnosis of the Tire Pres-
sure Monitoring System.
STANDARD PROCEDURE - TIRE PRESSURE
SENSOR RETRAIN
WARNING: DEATH OR SERIOUS INJURY CAN
OCCUR IF MAGNETICALLY SENSITIVE DEVICES
ARE EXPOSED TO THE RELEARN MAGNET. MAG-
NETS CAN AFFECT PACEMAKERS.
22 - 10 TIRES/WHEELSRS
TIRE PRESSURE MONITORING (Continued)

white letters. To remove the protective coating, apply
warm water and let it soak for a few minutes. After-
wards, scrub the coating away with a soft bristle
brush. Steam cleaning may also be used to remove
the coating.
CAUTION: DO NOT use gasoline, mineral oil, oil-
based solvent or a wire brush for cleaning.
WHEELS
DESCRIPTION - WHEEL
Original equipment wheels are designed for proper
operation at all loads up to the specified maximum
vehicle capacity.
All models use either steel or aluminum drop-cen-
ter wheels. Every wheel has raised sections between
the rim flanges and rim drop well called safety
humps (Fig. 28). Initial inflation of the tires forces
the bead over these raised sections. In case of air
loss, the safety humps hold the tire in position on the
wheel until the vehicle can be brought to a safe stop.
Cast aluminum wheels require special balance
weights to fit on the flange of the rim (Fig. 29).
When wheel alignment is necessary on a vehicle
with cast aluminum wheels, special wheel clamps are
required to avoid damage to the wheel's finish.
The wheel studs and nuts are designed for specific
wheel applications and must be replaced with equiv-
alent parts.
All aluminum wheels have wheel mounting (lug)
nuts with an enlarged nose. This enlarged nose is
necessary to ensure proper retention of the wheels.
DIAGNOSIS AND TESTING - WHEEL
INSPECTION
Inspect wheels for:
²Excessive runout
²Dents, cracks or irregular bends
²Damaged wheel stud (lug) holes
²Air Leaks
NOTE: Do not attempt to repair a wheel by hammer-
ing, heating or welding.
If a wheel is damaged, an original equipment
replacement wheel should be used. When obtaining
replacement wheels, they must be equivalent in load
carrying capacity. The diameter, width, offset, pilot
hole and bolt circle of the wheel should be the same
as the original wheel.
WARNING: FAILURE TO USE EQUIVALENT
REPLACEMENT WHEELS MAY ADVERSELY
AFFECT THE SAFETY AND HANDLING OF THE
VEHICLE.
WARNING: REPLACEMENT WITH USED WHEELS IS
NOT RECOMMENDED. THE SERVICE HISTORY OF
THE WHEEL MAY HAVE INCLUDED SEVERE TREAT-
MENT OR VERY HIGH MILEAGE. THE RIM COULD
FAIL WITHOUT WARNING.
CLEANING - ALUMINUM WHEEL CARE
Chrome plated and painted aluminum wheels
should be cleaned regularly using mild soap and
water to maintain their luster and to prevent corro-
sion.
Fig. 28 Safety Rim
1 - TIRE
2 - WELL
3 - SAFETY HUMPS
4 - FLANGE
Fig. 29 Styled Aluminum Wheel Weight
1 - TIRE
2 - WHEEL
3 - STYLED WHEEL WEIGHT
22 - 18 TIRES/WHEELSRS
TIRES (Continued)

TIRES/WHEELS
TABLE OF CONTENTS
page page
TIRE PRESSURE MONITORING............... 1TIRES................................... 5
TIRE PRESSURE MONITORING
TABLE OF CONTENTS
page page
TIRE PRESSURE MONITORING DESCRIPTION ..........................1
OPERATION ............................1
SENSOR - TPM DESCRIPTION ..........................1
OPERATION ............................2
CAUTION ..............................2 DIAGNOSIS AND TESTING - TIRE PRESSURE
SENSOR .............................2
STANDARD PROCEDURE - TIRE PRESSURE SENSOR RETRAIN .....................2
REMOVAL .............................2
INSTALLATION ..........................3
TIRE PRESSURE MONITORING
DESCRIPTION
Some versions of this vehicle are equipped with a
Tire Pressure Monitoring (TPM) system. It monitors
air pressure in the four road tires. Pressure in the
spare tire is not monitored. There is a sensor (transmitter) in each of the vehi-
cle's four road wheels that is built in to the valve
stem. The system alerts the driver when tire pres-
sure falls outside predetermined thresholds (pressure
too low or too high). A message is then displayed on
the Compass Mini Trip Computer (CMTC). For further information, refer to the Owners Man-
ual or the appropriate diagnostic information.
OPERATION
The Tire Pressure Monitoring (TPM) system uses
radio and sensor technology to monitor tire air pres-
sure levels. Sensors, mounted to each road wheel as
part of the valve stem, transmit an RF frequency
indicating their individual pressure to a receiver
located in the Sentry Key Remote Entry Module
(SKREEM). These transmissions occur approximately
once every minute at speeds over 13 mph (20 km/h).
The Tire Pressure Monitoring system remains active
even if no tire pressure related message is displayed.
SENSOR - TPM
DESCRIPTION
On vehicles equipped with Tire Pressure Monitor-
ing, one tire pressure sensor is mounted to each
wheel (Fig. 2). Each sensor has an internal battery
that lasts up to 10 years. The battery is not service-
able. At the time of battery failure, the sensor must
be replaced. The serviceable components of the tire
pressure sensor are: ² Sensor-To-Wheel Grommet
² Valve Stem Cap
² Valve Stem Core
Valve stem caps and cores are specifically designed
for the tire pressure monitoring sensors. Although
similar to standard valve stem caps and cores, they
are different.
CAUTION: Do not use a standard valve stem cap or
core in a tire pressure sensor. Always use the orig-
inal equipment style sensor cap and core.
CAUTION: Do not reuse the Sensor-To Wheel Grom-
met. Always use a new grommet when installing a
pressure sensor and properly torque the sensor
nut.
RS TIRES/WHEELS22s-1

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Lifgate stabilizer wedge striker to D-pillar bolts 3 Ð 30
Luggage rack crossbar fasteners 4 Ð 35
Lumbar support handle screw 1 Ð 9
Pivot bolt to the body half of hood hinge 28 21 Ð
Prop assembly to lifgate bolts 28 21 Ð
Rear door glass to regulator bolt 11 8 Ð
Rear door hinge to B-pillar bolt 28 20 Ð
Rear door hinge to door bolt 28 20 Ð
Rear door latch striker 28 20 Ð
Rear latch to sliding door end frame 28 20 Ð
Rear seat back to seat cushion bolt 27 19 Ð
Recliner to seat back frame 12 9 Ð
Seatback frame upper rail 8 Ð 71
Seatback hinge bolt 48 35 Ð
Seatback hinge cover screws 2.3 Ð 20
Shoulder belt turning loop onto height adjuster 39 29 Ð
Side view mirror bolts 10 Ð 85
Sliding door center hinge adjusting bolt 15 Ð 130
Sliding door glass nuts 3.4 Ð 30
Sliding door latch striker 28 21 Ð
Sliding door to roller arm bracket 12 9 Ð
Storage bin track guide to seat riser 3.5 Ð 31
Sunroof opening panel to lifter arm screws 5 44
Sunroof opening panel motor screws 4 35
Sunroof trough bracket to roof bolts 6 53
Sunroof trough to trough bracket bolts 6 53
Sunroof trough bracket bolts 6 53
Support cylinders to liftgate 28 21 Ð
BODY LUBRICATION
LUBRICATION REQUIREMENTS
Body mechanisms and linkages should be
inspected, cleaned, and lubricated, as required, to
maintain ease of operation and to provide protection
against rust and wear. When performing other under
hood services, the hood latch release mechanism and
safety catch should be inspected, cleaned, and lubri-
cated. During the winter season, external door lock
cylinders should be lubricated to assure proper oper-
ation when exposed to water and ice.
Prior to the application of any lubricant, the parts
concerned should be wiped clean to remove dust and
grit. If necessary, a suitable solvent can be used to
clean the item to be lubricated. After lubricating acomponent, any excess oil or grease should be
removed.LUBRICANT APPLICATION
DOOR LOCK CYLINDERS
(1) Apply a small amount of lubricant directly into
the lock cylinder.
(2) Apply a small amount of lubricant to the key.
(3) Insert key into lock cylinder and cycle the
mechanism from the locked to the unlocked position.
NOTE: Do not add more lubricant.
(4) Cycle the lock cylinder mechanism several
times to allow the lubricant to flow throughout the
cylinder.
23 - 12 BODYRS
BODY (Continued)

FRONT SEAT BACK
REMOVAL
NOTE: On front seats equipped with side air bags,
the seatback is serviced as an assembly.
(1) Remove head rest sleeves. (Refer to 23 - BODY/
SEATS/HEADREST SLEEVE - REMOVAL)
(2) Remove the armrest. (Refer to 23 - BODY/
SEATS/ARMREST - REMOVAL)
(3) Remove the seatback recliner lever.
(4) Remove the lumbar adjustment lever.
(5) Remove both seat cushion side covers. (Refer to
23 - BODY/SEATS/FRONT SEAT CUSHION SIDE
COVER - REMOVAL)
(6) Remove nut attaching the recliner to the seat-
back frame (Fig. 15).
(7) Remove both pivot bolts and remove seatback
from recliner.
INSTALLATION
(1) Place seat back into position.
(2) Install both pivot bolts attaching seat back
frame to seat track. Tighten bolts to 54 N´m (40 ft.
lbs.) torque.(3) Install nut attaching the recliner to the seat
back frame. Tighten nut to 12 N´m (105 in. lbs.)
torque.
(4) Install both seat cushion side covers. (Refer to
23 - BODY/SEATS/FRONT SEAT CUSHION SIDE
COVER - INSTALLATION)
(5) Install the lumbar adjustment lever.
(6) Install the seat back recliner lever.
(7) Install the armrest. (Refer to 23 - BODY/
SEATS/ARMREST - INSTALLATION)
(8) Install headrest sleeves. (Refer to 23 - BODY/
SEATS/HEADREST SLEEVE - INSTALLATION)
FRONT SEATBACK ASSIST
STRAP
REMOVAL
(1) Using a small screw driver, pry screw plugs
from ends of assist strap (Fig. 16).
(2) Remove screws attaching assist strap to seat-
back.
(3) Remove assist strap from vehicle.
INSTALLATION
(1) Place assist strap in position on vehicle.
(2) Install screws attaching assist strap to seat
back. Tighten screws to 2.5 N´m (22 in. lbs.).
(3) Insert screw plugs into ends of assist strap
(Fig. 16).
FRONT SEATBACK PANEL
REMOVAL
(1) Remove the screws (Fig. 17).
(2) Tip the top of the panel away from the seat
back and lift off the hooks at the bottom to remove.
Fig. 15 FRONT SEATBACK
Fig. 16 FRONT SEATBACK ASSIST STRAP
1 - ASSIST STRAP
2 - SCREW PLUG
3 - SEAT BACK
23 - 92 SEATSRS

INSTALLATION
(1) Place seat back cover onto the seat and engage
the bottom hooks.
(2) Install the top screws.
FRONT SEATBACK COVER
REMOVAL
NOTE: On vehicles equipped with seat side air bags
the seat cover is NOT serviceable. The seat back is
serviced as an assembly. (Refer to 23 - BODY/
SEATS/SEAT BACK - REMOVAL)
(1) Remove the seat back. (Refer to 23 - BODY/
SEATS/FRONT SEATBACK - REMOVAL)
(2) Unclip J-straps as necessary.
(3) Remove seat back cover from seat back cushion
and frame assembly.
INSTALLATION
NOTE: On vehicles equipped with seat side air bags
the seat cover is NOT serviceable. The seat back is
serviced as an assembly only. (Refer to 23 - BODY/
SEATS/SEAT BACK - INSTALLATION)
(1) Fit seat cover onto seat back cushion and
frame assembly.(2) Connect the J-straps.
(3) Install the seat back. (Refer to 23 - BODY/
SEATS/FRONT SEATBACK - INSTALLATION)
FRONT/QUAD SEAT CUSHION
REMOVAL
(1) Remove seat cushion side covers, and leave
connector connected, if equipped. (Refer to 23 -
BODY/SEATS/FRONT SEAT CUSHION SIDE
COVER - REMOVAL)
(2) On quad buckets, remove the seat side shield
and cup holder. (Refer to 23 - BODY/SEATS/SEAT
SIDE SHIELD/QUAD BUCKET SEAT SIDE
SHIELD/CUP HOLDER - REMOVAL) and (Refer to
23 - BODY/SEATS/QUAD BUCKET SEAT SIDE
SHIELD - NO CUP HOLDER - REMOVAL)
(3) Remove seat track front and rear covers if
equipped. (Refer to 23 - BODY/SEATS/SEAT TRACK
REAR COVER - REMOVAL) and (Refer to 23 -
BODY/SEATS/SEAT TRACK FRONT COVER -
REMOVAL)
(4) If equipped, open storage bin to access front
pan bolts.
(5) Remove bolts attaching seat cushion pan to
seat track.
(6) Disconnect wire connectors, if equipment.
(7) Remove seat cushion from seat.
(8) Disengage J-strap retainers holding seat cover
to cushion.
(9) Remove seat cushion pan from cover and pad.
INSTALLATION
(1) Place seat cushion cover in position on seat
cushion.
(2) Engage J-strap retainers to hold seat cover to
cushion.
(3) Place seat cushion in position on seat.
(4) Connect wire connectors, if equipment.
(5) Install bolts attaching seat cushion to seat
track. Tighten bolts to 28.5 N´m (21 ft. lbs.) torque.
(6) If equipped, close storage bin.
(7) Install seat track front and rear covers, if
equipped. (Refer to 23 - BODY/SEATS/SEAT TRACK
REAR COVER - INSTALLATION) and (Refer to 23 -
BODY/SEATS/SEAT TRACK FRONT COVER -
INSTALLATION)
(8) Install the quad seat side shield and cup holder
if equipped. (Refer to 23 - BODY/SEATS/QUAD
BUCKET SEAT SIDE SHIELD/CUP HOLDER -
INSTALLATION) and (Refer to 23 - BODY/SEATS/
QUAD BUCKET SEAT SIDE SHIELD - NO CUP
HOLDER - INSTALLATION)
Fig. 17 FRONT SEATBACK PANEL - TYPICAL
1 - SCREWS
2 - SEAT BACK PANEL
3 - SEAT BACK
RSSEATS23-93
FRONT SEATBACK PANEL (Continued)