2005 CHRYSLER VOYAGER warning

(3) Install new O-rings on ends of power steering
fluid pressure hose. Lubricate O-rings using clean
power steering fluid.
CAUTION: Use care not to bend tube ends of the
power steering hoses when installing. Leaks and
restrictions may occur.
CAUTION: Power steering fluid hoses must remain
away from the exhaust system and must not come
in contact with any unfriendly surfaces on the vehi-
cle.
(4) Route hose up behind engine toward pump
avoiding tight bends or kinking.
(5) Install power steering pressure hose end into
pump pressure outlet fitting (Fig. 22). Thread tube
nut into outlet fitting, but do not tighten at this time.
(6) Attach pressure hose routing bracket to engine
(Fig. 22). Tighten bolt to 23 N´m (200 in. lbs.) torque.
(7) Tighten hose tube nut at pump outlet fitting to
31 N´m (275 in. lbs.) torque.
(8) Route hose behind cradle crossmember and
start hose end into gear port. Do not tighten hose
tube nut at this time.
(9) Attach hose to suspension cradle crossmember
and steel reinforcement using two routing clamps
and bolts (Fig. 21). Tighten clamp bolt at steel rein-
forcement to 11 N´m (100 in. lbs.) torque. Tighten
clamp bolt at cradle crossmember to 23 N´m (200 in.
lbs.) torque.
(10) Tighten hose tube nut at power steering gear
port to 31 N´m (275 in. lbs.) torque.
(11) Install front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - INSTALLATION)
(12) Lower vehicle.
(13) Fill and bleed the power steering system
using the Power Steering Pump Initial Operation
Procedure. (Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE)
(14) Inspect system for leaks.
HOSE - POWER STEERING
RETURN
REMOVAL
REMOVAL - 2.4L ENGINE
NOTE: Before proceeding, review all WARNINGS
and CAUTIONS. (Refer to 19 - STEERING/PUMP -
WARNING)(Refer to 19 - STEERING/PUMP - CAU-
TION)(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(3) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Remove front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - REMOVAL)
(5) Place an oil drain pan under vehicle to catch
power steering fluid.
(6) Cut tie-strap securing insulating heat sleeve to
power steering fluid return hose near power steering
pump. Pull back heat sleeve to expose hose clamp.
(7) Remove clamp, then return hose from power
steering pump (Fig. 20).
(8) Remove 2 bolts attaching power steering cooler
to cradle crossmember reinforcement (Fig. 24).
(9) Remove bolts attaching routing clamps to front
suspension cradle crossmember (Fig. 20). Remove
return hose from clamps.
(10) Back out return hose tube nut at power steer-
ing gear and remove hose (Fig. 20).
REMOVAL - 3.3L/3.8L ENGINE
NOTE: Before proceeding, review all WARNINGS
and CAUTIONS. (Refer to 19 - STEERING/PUMP -
WARNING)(Refer to 19 - STEERING/PUMP - CAU-
TION)
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(3) Place an oil drain pan under vehicle to catch
any draining power steering fluid.
(4) Remove clamp attaching return hose to power
steering fluid reservoir. Disconnect hose from reser-
voir (Fig. 22).
(5) Follow return hose downward and open
retainer at ABS bracket (Fig. 21). Remove hose tube
from retainer.
(6) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(7) Remove front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - REMOVAL)
(8) Remove bolt securing return hose routing
clamp to suspension cradle crossmember (Fig. 21).
RSPUMP19-49
HOSE - POWER STEERING PRESSURE (Continued)

(4) Route hose (with cooler attached) up toward
reservoir avoiding tight bends or kinking.
(5) Start steering gear end of hose into gear port.
Do not tighten hose tube nut at this time.
(6) Attach return hose tubes to suspension cradle
crossmember using routing clamp and bolt (Fig. 21).
Tighten clamp bolt to 23 N´m (200 in. lbs.) torque.
(7) Install the power steering fluid cooler on the
cradle crossmember reinforcement (Fig. 24). Install
the mounting bolts and tighten to 11 N´m (100 in.
lbs.). When installing mounting bolts, include pres-
sure hose routing clamp.
(8) Tighten hose tube nut at power steering gear
port to 31 N´m (275 in. lbs.) torque.
(9) Install front emissions vapor canister. (Refer to
25 - EMISSIONS CONTROL/EVAPORATIVE EMIS-
SIONS/VAPOR CANISTER - INSTALLATION)
(10) Lower vehicle.
(11) Install return hose tube into retainer on ABS
bracket (Fig. 21). Close the bracket.
(12) Install return hose onto reservoir (Fig. 22).
Slide the hose clamp into position on fluid reservoir
and attach it.Be sure hose clamp in installed
past bead on fluid reservoir fitting.
(13) Fill and bleed power steering system using
the Power Steering Pump Initial Operation Proce-
dure. (Refer to 19 - STEERING/PUMP - STANDARD
PROCEDURE)
(14) Inspect system for leaks.
HOSE - POWER STEERING
SUPPLY
REMOVAL
REMOVAL - 2.4L ENGINE
(1) Remove filler cap from power steering fluid res-
ervoir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(3) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Remove hose clamp securing supply hose to
power steering pump, then remove supply hose from
pump fitting.
(5) Lower vehicle.
(6) Remove hose clamp attaching power steering
fluid supply hose to power steering fluid reservoir,
then remove supply hose.
(7) Remove the power steering fluid supply hose
from the vehicle.
REMOVAL - 3.3L/3.8L ENGINE
NOTE: Before proceeding, review all WARNINGS
and CAUTIONS. (Refer to 19 - STEERING/PUMP -
WARNING)(Refer to 19 - STEERING/PUMP - CAU-
TION)
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(3) Place an oil drain pan under vehicle to catch
any draining power steering fluid.
(4) Remove clamp attaching supply hose to power
steering fluid reservoir. Disconnect hose from reser-
voir (Fig. 22).
(5) Pull upward on hose routing clip releasing it
from bracket on cylinder head cover (Fig. 22).
NOTE: It may be necessary to remove air cleaner
housing to gain greater access to supply hose at
power steering pump. (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL)
(6) Remove clamp attaching supply hose to power
steering pump. Disconnect hose from pump and
remove from vehicle (Fig. 22).
INSTALLATION
INSTALLATION - 2.4L ENGINE
(1) Install and correctly route power steering fluid
supply hose from remote fluid reservoir to power
steering pump.
(2) Install fluid supply hose onto power steering
fluid reservoir. Install hose clamp.Be sure hose
clamp is installed past bead on fluid reservoir
fitting.
(3) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Install power steering fluid supply hose on
power steering pump supply fitting. Install hose
clamp.Be sure hose clamp is installed past bead
on pump fitting.
(5) Lower vehicle.
(6) Fill and bleed power steering system using
Power Steering Pump Initial Operation Procedure.
(Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE)
(7) Inspect system for leaks.
RSPUMP19-51
HOSE - POWER STEERING RETURN (Continued)

(3) Using a plastic hammer, remove extension
housing/adapter plate on the right side of the trans-
axle.
WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY
TO PREVENT IT FROM ROLLING OUT OF HOUSING.
(4) Remove differential assembly.
(5) Set up dial indicator set C-3339 and tool
C-4996 as shown in (Fig. 173) (Fig. 174) to measure
side gear end play.Side gear end play must be
within 0.001-0.013 in.(6) Use Miller Special Tool 5048, 5048-3 Collets,
and L-4539-2 Button to remove the differential bear-
ing cone on the extension housing side.
Fig. 172 Remove Bearing Retainer
1 - DIFFERENTIAL BEARING RETAINER
2 - TOOL L-4435
Fig. 173 Checking Side Gear End Play (Extension
Housing Side)
1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
3 - DIFFERENTIAL ASSEMBLY
4 - SIDE GEAR
Fig. 174 Checking Side Gear End Play (Ring Gear
Side)
1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
3 - DIFFERENTIAL ASSEMBLY
21 - 76 40TE AUTOMATIC TRANSAXLERS
FINAL DRIVE (Continued)

OPERATION
The differential assembly is driven by the transfer
shaft by way of the differential ring gear. The ring
gear drives the differential case, and the case drives
the driveshafts through the differential gears. The
differential pinion and side gears are supported in
the case by thrust washers and a pinion shaft. Dif-
ferential pinion and side gears make it possible for
front tires to rotate at different speeds while corner-
ing.
DISASSEMBLY
NOTE: The differential is serviced as an assembly.
Differential service is limited to bearing cups and
cones. Any other differential component failure
must be remedied by differential assembly and
transfer shaft replacement.
The transfer shaft should be removed for differen-
tial repair and bearing turning torque checking.
(1) Remove the differential cover and bolts (Fig.
169) (Fig. 170).
(2) Remove the differential bearing retainer and
bolts (Fig. 171) (Fig. 172).
(3) Using a plastic hammer, remove extension
housing/adapter plate on the right side of the trans-
axle.
WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY
TO PREVENT IT FROM ROLLING OUT OF HOUSING.
(4) Use Miller Special Tool 5048, 5048-3 Collets,
and L-4539-2 Button to remove the differential bear-
ing cone on the extension housing side.
Fig. 169 Differential Cover Bolts
1 - DIFFERENTIAL COVER BOLTS
2 - DIFFERENTIAL COVER
Fig. 170 Remove Differential Cover
1 - DIFFERENTIAL ASSEMBLY
2 - DIFFERENTIAL COVER
Fig. 171 Differential Retainer Bolts
1 - DIFFERENTIAL RETAINER BOLTS
Fig. 172 Remove Bearing Retainer
1 - DIFFERENTIAL BEARING RETAINER
2 - TOOL L-4435
21 - 220 41TE AUTOMATIC TRANSAXLERS
FINAL DRIVE (Continued)

(3) Place the wheel cover on the wheel in the fol-
lowing fashion:
(a) Align the valve notch in the wheel cover with
the valve stem on the wheel.
(b) At the same time, align the two holes in the
wheel cover having the retaining tabs with the two
installed wheel nuts (Fig. 15).
(c) Press in on center of wheel cover until wheel
cover retaining tabs push past and engage rear of
previously installed wheel mounting nuts (Fig. 15).
This will hold the wheel cover in place.(4) Install andlightly tightenthe three remain-
ing wheel mounting nuts, securing the wheel cover in
place (Fig. 12).
(5) Progressively tighten all five wheel mounting
nuts in the proper sequence (Fig. 16). Tighten wheel
nuts to a torque of 135 N´m (100 ft. lbs.).
(6) Lower the vehicle.
TIRE PRESSURE MONITORING
DESCRIPTION
Some versions of this vehicle are equipped with
Tire Pressure Monitoring (TPM). TPM monitors air
pressure in the four road tires. The system alerts the
driver when tire pressure in any of the four road
wheels falls below a predetermined threshold (pres-
sure too low).
Depending on optional equipment, a vehicle may
have four or five sensors (fifth sensor located in spare
wheel). Although a pressure sensor may be present in
the spare tire wheel of the five sensor system, pres-
sure in the spare tire is not monitored.
There are two systems available, Base and Pre-
mium. The Base system offers an indicator lamp,
warning the driver of a pressure issue. An audible
chime also sounds once when a pressure issue occurs.
In addition to these features, the Premium system
offers an Electronic Vehicle Information Center
(EVIC) display of information.
For further information, refer to the Owners Man-
ual or the appropriate diagnostic information.
Fig. 14 TWO WHEEL MOUNTING NUTS INSTALLED
1 - WHEEL
2 - VALVE STEM
3 - HUB PILOT
4 - NUTS
Fig. 15 WHEEL COVER INSTALLATION OVER TWO
NUTS
1 - RETAINING TABS
2 - VALVE STEM
3 - BOLT-ON WHEEL COVER
Fig. 16 NUT TIGHTENING SEQUENCE
RSTIRES/WHEELS22-9
TIRES/WHEELS (Continued)

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 a low frequency indi-
cating their individual pressure to a receiver located
in the Wireless Control Module (WCM) portion of the
Sentry Key Remote Electronic Entry Module
(SKREEM). These transmissions occur approximately
once every minute at speeds over 20 mph (32 km/h).
The Tire Pressure Monitoring system remains active
even if no tire pressure related message is displayed.
The sensors lay dormant (Park Mode), then wake
and start transmitting (Drive Mode) when the vehicle
first reaches speeds over 20 mph (32 km/h). Once the
wheels stop rotating for a period of approximately 30
minutes, the sensors shut down until again awaken.
Although not transmitting as when in Drive Mode,
while in Park Mode, the sensors still transmit
approximately once every 13 hours to let the receiver
know air pressure status at that time.
The receiver only receives information from the
four rotating tires. A fifth sensor may be located in
the spare tire wheel, depending on vehicle options.
Although this fifth sensor may be present, it does not
broadcast any information because it does not rotate.
When the system detects that a tire is going low,
below the Low Pressure (lamp) ON Threshold (See
following table), the driver is alerted to the situation.
The Base system illuminates an indicator lamp,
warning the driver of a pressure issue and sounds an
audible chime. In equipped with the Premium sys-
tem, the information is also displayed on the Elec-
tronic Vehicle Information Center (EVIC).
Once pressure in the suspect tire raises above the
Low Pressure (lamp) OFF Threshold, the lamp will
go out and the system returns to normal.
TPM THRESHOLD PRESSURES
DESCRIPTION SPECIFICATION
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 road
wheel (Fig. 18), and depending on factory wheel
options, a sensor may be located in the spare tire
wheel. Both aluminum and steel wheels are used in
this system, although sensors for one type wheel can-
not be used in the other type wheel.Each sensor has an internal battery that lasts up
to 10 years. The battery is not serviceable. At the
time of battery failure, the sensor must be replaced.
The serviceable components of the tire pressure sen-
sor 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 attempt to install a tire pressure
sensor in an aftermarket wheel. Use only in original
style factory wheels.
OPERATION
The battery operated tire pressure sensors lay dor-
mant (Park Mode), then wake and start transmitting
(Drive Mode) when the vehicle first reaches speeds
over 20 mph (32 km/h). Once the wheels stop rotat-
ing for a period of approximately 30 minutes, the
sensors shut down until again awaken. Although not
transmitting as when in Drive Mode, while in Park
Mode, the sensors still transmit approximately once
every 13 hours to let the receiver know air pressure
status at that time.
Each sensor transmits tire pressure data approxi-
mately once every minute. Each sensor's (transmit-
ter) broadcast is uniquely coded so that the wireless
control module (WCM) can monitor the state of each
of the sensors on the four rotating road wheels. The
WCM (located in the SKREEM) automatically learns
and stores the sensor's ID while driving after a sen-
sor has been replaced. There is no retraining neces-
sary.
The receiver only receives information from the
four rotating tires. A fifth sensor may be located in
the spare tire wheel, depending on vehicle options.
Although this fifth sensor may be present, it does not
broadcast any information because it does not rotate.
For additional information, refer to Appropriate
Diagnostic Information.
22 - 10 TIRES/WHEELSRS
TIRE PRESSURE MONITORING (Continued)

Radial-ply tires must always be used in sets of four
and under no circumstances should they be used on
the front only. It is recommended that tires from dif-
ferent manufacturers NOT be mixed. They may be
mixed with a temporary spare tire when necessary. A
maximum speed of 80 km/h (50 mph) is recom-
mended while a temporary spare is in use.
Radial-ply tires have the same load-carrying capac-
ity as other types of tires of the same size. They also
use the same recommended inflation pressures.
DESCRIPTION - REPLACEMENT TIRES
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
WARNING: IN ORDER TO MAINTAIN THE SPEED
CAPABILITY OF THE VEHICLE, REPLACEMENT
TIRES MUST HAVE SPEED RATINGS EQUAL TO OR
HIGHER THAN THOSE FITTED TO THE VEHICLE AS
ORIGINAL EQUIPMENT. IF TIRES WITH LOWER
SPEED RATINGS ARE FITTED, THE VEHICLE'S
HANDLING MAY BE AFFECTED AND THE SPEED
CAPABILITY OF THE VEHICLE MAY BE LOWERED
TO THE MAXIMUM SPEED CAPABILITY OF THE
REPLACEMENT TIRES. TO AVOID AN ACCIDENT
RESULTING IN SEVERE OR FATAL INJURY, CON-
SULT THE TIRE MANUFACTURER IN REGARDS TO
MAXIMUM SPEED RATINGS.
It is recommended that tires equivalent to the orig-
inal equipment tires be used when replacement is
needed.
Failure to use equivalent replacement tires may
adversely affect the safety and handling of the vehi-
cle.
The original equipment tires provide a proper com-
bination of many characteristics such as:
²Ride
²Noise
²Handling
²Durability
²Tread life²Traction
²Rolling resistance
²Speed capability
The use of tires smaller than the minimum tire
size approved for the vehicle can result in tire over-
loading and failure.
Use tires that have the approved load rating for
the vehicle and never overload them. Failure to equip
the vehicle with tires having adequate speed capabil-
ity can result in sudden tire failure and loss of vehi-
cle control.
The use of oversize tires may cause interference
with vehicle components. Under extremes of suspen-
sion and steering travel, interference with vehicle
components may cause tire damage.
DESCRIPTION - SPARE TIRE (TEMPORARY)
The temporary (convenience) spare tire is designed
for emergency use only. The original tire should be
repaired and reinstalled, or replaced with a new, at
the first opportunity.
The temporary (convenience) spare tire should be
inflated to the pressure listed on its sidewall. Do not
exceed speeds of 80 km/h (50 mph) when the tempo-
rary spare tire is in use on the vehicle. Refer to the
Owner's Manual for more details.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - TIRE NOISE
Unusual tire noise can be associated with tire and
wheel vibration or irregular tire wear. For vibration,
(Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
TESTING). For irregular tire wear, (Refer to 22 -
TIRES/WHEELS/TIRES - DIAGNOSIS AND TEST-
ING).
DIAGNOSIS AND TESTING - TIRE/VEHICLE
LEAD
Use the following Vehicle Lead Diagnosis And Cor-
rection Chart to diagnose and correct a vehicle lead
or drift problem.
22 - 14 TIRES/WHEELSRS
TIRES (Continued)

Inflation pressures specified on the Tire Inflation
Pressure Label are always the cold inflation pressure
of the tire. Cold inflation pressure is obtained after
the vehicle has not been operated for at least 3
hours, or the vehicle is driven less than one mile
after being inoperative for 3 hours. Tire inflation
pressures may increase from 2 to 6 pounds per
square inch (psi) (14 to 41 kPa) during operation. Do
not reduce this normal pressure buildup.
Improper inflation can cause:
²Uneven wear patterns
²Reduced tread life
²Reduced fuel economy
²Unsatisfactory ride
²The vehicle to drift.
WARNING: OVER OR UNDER INFLATED TIRES CAN
AFFECT VEHICLE HANDLING. THE TIRE CAN FAIL
SUDDENLY, RESULTING IN LOSS OF VEHICLE
CONTROL.
Under inflation causes rapid shoulder wear, tire
flexing, and can result in tire failure (Fig. 24).
Over inflation causes rapid center wear and loss of
the tire's ability to cushion shocks (Fig. 25).
STANDARD PROCEDURE - TIRE PRESSURE
FOR HIGH SPEED OPERATION
DaimlerChrysler Corporation advocates driving at
safe speeds within posted speed limits. Where speed
limits allow the vehicle to be driven at high speeds,
correct tire inflation pressure is very important.
Vehicles loaded to maximum capacity should not be
driven at continuous speeds over 120 km/h (75 mph).
Never exceed the maximum speed capacity of the
tire. For information on tire identification and speed
ratings, (Refer to 22 - TIRES/WHEELS/TIRES -
DESCRIPTION).
STANDARD PROCEDURE - TIRE LEAK
REPAIRING
For proper repairing, a radial tire must be removed
from the wheel. Repairs should only be made if the
defect, or puncture, is in the tread area (Fig. 26). The
tire should be replaced if the puncture is located in
the sidewall.
Deflate tire completely before attempting to dis-
mount the tire from the wheel.Use a lubricant
such as a mild soap solution when dismounting
or mounting tire.Use tools free of burrs or sharp
edges which could damage the tire or wheel rim.
Before mounting tire on wheel, make sure all rust
is removed from the rim bead and repaint if neces-
sary.
Install wheel on vehicle, and progressively tighten
the 5 wheel nuts to a torque of 135 N´m (100 ft. lbs.).
Fig. 24 Under Inflation Wear
1 - THIN TIRE TREAD AREAS
Fig. 25 Over Inflation Wear
1 - THIN TIRE TREAD AREA
RSTIRES/WHEELS22-17
TIRES (Continued)