2005 CHRYSLER VOYAGER Service Manual

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Page 473 of 2339

CHRYSLER VOYAGER 2005 Service Manual (5) Partially close the door and pull the latch
assembly out of the side door inner panel, (Fig. 5).
(6) Disconnect all electrical connectors leading to
the latch assembly.
(7) Disconnect the inside a

Page 474 of 2339

CHRYSLER VOYAGER 2005 Service Manual SLIDING DOOR MOTOR
DESCRIPTION
The door motor is located in the center of the
power sliding door (Fig. 8) and is comprised of three
parts. The three parts of the door motor assembly are
the motor, gea

SLIDING DOOR MOTOR
DESCRIPTION
The door motor is located in the center of the
power sliding door (Fig. 8) and is comprised of three
parts. The three parts of the door motor assembly are
the motor, gear reduction and clutch assembly. The
door motor assembly provides the power and torque
to move the sliding door from the open/closed posi-
tion to full closed/open position, after the power
latching mechanism has released.
The door motor is replaced as a complete assembly,
which includes the DC motor, gear reduction and
clutch assemblies.
OPERATION
With the push of a power sliding door command
switch, the power sliding door control module will
signal the latch assembly to release the door from its
primary locked position. The door motor will then
take over to provide the power to open the door to its
full open or closed position. The gear reduction por-
tion of the motor assembly reduces the speed of the
motor from 5800 to 260 rpm and also increases the
torque to the lower drive unit. The clutch portion of
the motor assembly engages the motor to drive thedoor under power and disengages it so the door can
be moved easily under manual operation.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the door trim panel from the appropri-
ate door, (Refer to 23 - BODY/DOORS - SLIDING/
TRIM PANEL - REMOVAL).
(3) Remove the water shield as necessary to gain
access to motor assembly.
(4) Remove retaining clip holding flex drive assem-
bly to the motor (Fig. 9). Pull flex drive cable straight
out of the motor assembly.
(5) Disconnect door motor electrical connector.
(6) Using a trim stick (special tool #C-4755) or
equivalent, gently pry out push-pin fasteners retain-
ing the door motor.
(7) Remove the door motor assembly from the
vehicle.
INSTALLATION
(1) Position the door motor assembly on the door
inner panel.
(2) Install the push-pin fasteners retaining the
motor assembly to the power sliding door.
Fig. 8 POWER SLIDING DOOR COMPONENTS
1 - POWER SLIDING DOOR CONTROL MODULE
2 - MODULE RETAINING SCREW
3 - MODULE ELECTRICAL CONNECTORS
4 - DOOR MOTOR ASSEMBLY
5 - FLEX DRIVE ASSEMBLY
6 - DOOR MOTOR RETAINING FASTENERS
7 - DOOR MOTOR ELECTRICAL CONNECTOR
Fig. 9 FLEX DRIVE RETAINING CLIP
1 - FLEX DRIVE CABLE RETAINING CLIP
2 - FLEX DRIVE CABLE
3 - DOOR MOTOR ASSEMBLY
RSPOWER SLIDING DOOR SYSTEM8N-51

Page 475 of 2339

CHRYSLER VOYAGER 2005 Service Manual NOTE: Push in on the push-pins at the clutch hous-
ing (plastic side) until you hear one click. Push in
on the push-pin fasteners at the motor mount
(sheet metal side) until you hear two clicks. This

NOTE: Push in on the push-pins at the clutch hous-
ing (plastic side) until you hear one click. Push in
on the push-pin fasteners at the motor mount
(sheet metal side) until you hear two clicks. This
assures proper installation/attachment of the motor
to the sliding door.
(3) Install the flex shaft by lining up the square
shaped drive shaft with the corresponding hole in the
door motor drive unit and push straight in.
(4) Install the E-clip to secure flex-shaft.
(5) Install the weather shield as necessary.
(6) Install the door trim panel on the sliding door,
(Refer to 23 - BODY/DOORS - SLIDING/TRIM
PANEL - INSTALLATION) for the procedure.
(7) Connect the battery negative cable.
FULL OPEN SWITCH
DESCRIPTION
The full open switch is located in the hold open
latch (Fig. 10) under the sliding door lower hinge.
When the power sliding door control module receives
a ground signal input from the full open switch, and
as long as the cinching latch actuator is not in power
mode or the handle switch is open, the signal indi-
cates that the door is at the full open position.The full open switch is incorporated into the hold
open latch. If the full open switch is inoperative, the
entire hold open latch assembly must be replaced.
OPERATION
The full open switch is triggered by a pawl lever in
the hold open latch. When the full open switch is
closed (circuit to ground) the ratchet has engaged on
the hold open striker and the pawl lever has engaged
on the ratchet, locking the latch from opening and
holding the door in the full open position.
B-PILLAR SWITCH
DESCRIPTION
The B-pillar switches are located on the interior of
the vehicle, on the B-pillar trim panels. These
switches serve as an open and close command switch
for the appropriate power sliding door.
OPERATION
When the B-pillar switch is depressed a signal is
sent to the Body Control Module (BCM), this signal
is then sent to the power sliding door control module,
telling it to start a power open or close cycle. The
child lockout feature must be disabled and the slid-
ing door must be unlocked in order for the B-pillar
switch to function.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Using a trim stick (special tool # C-4755) or
equivalent, gently pry the leading upper edge of the
B-pillar switch away from the B-pillar trim.
(3) Once the upper edge is free from B-pillar trim,
rock the switch out of the switch opening.
(4) Disconnect the B-pillar switch electrical con-
nector. First, slide the connector lock away from the
switch then, depress connector retaining tab while
pulling straight apart.
(5) Remove the B-pillar switch from the vehicle.
INSTALLATION
(1) Connect the B-pillar switch electrical connector.
Slide connector lock toward the switch to lock in
place.
(2) Hook the lower edge of the B-pillar switch on
the B-pillar trim and then push the switch firmly
into position.
(3) Connect the battery negative cable.
Fig. 10 FULL OPEN SWITCH POSITION &
ORIENTATION
1 - HOLD OPEN LATCH ASSEMBLY
2 - HOLD OPEN LATCH CABLE
3 - FULL OPEN SWITCH
8N - 52 POWER SLIDING DOOR SYSTEMRS
SLIDING DOOR MOTOR (Continued)

Page 476 of 2339

CHRYSLER VOYAGER 2005 Service Manual LOWER DRIVE UNIT
DESCRIPTION
The lower drive unit is located on the power sliding
door lower hinge assembly (Fig. 11). This drive unit
is used to transfer the rotation of the flex drive
assembly into

Page 477 of 2339

CHRYSLER VOYAGER 2005 Service Manual INSTALLATION
(1) Position the lower drive unit near the lower
hinge.
(2) Connect the flex drive assembly on the lower
drive unit. Push the flex drive collar straight on until
the it snaps in place (Fi

Page 478 of 2339

CHRYSLER VOYAGER 2005 Service Manual FLEX DRIVE
DESCRIPTION
The flex drive assembly is located in the lower por-
tion of the power sliding door (Fig. 17) and is used to
connect the door motor to the lower drive unit. An
E-clip is used to

Page 479 of 2339

CHRYSLER VOYAGER 2005 Service Manual (6) Remove the lower drive unit cover retaining
screws and remove the cover (Fig. 19).
(7) Expand the flex drive collar, next to the lower
drive unit until the flex drive can be pulled straight
off th

Page 480 of 2339

CHRYSLER VOYAGER 2005 Service Manual LOWER DRIVE UNIT TRACK &
RACK
DESCRIPTION
The door track and rack assembly provides a mat-
ing rack gear (Fig. 22) for the lower drive unit to
engage. The track also accepts the lower hinge roll-
ers,

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