2005 CHRYSLER VOYAGER diagram

SCHEMATICS AND DIAGRAMS
4XTE TRANSAXLE HYDRAULIC SCHEMATICS
Park/Neutral (Speed Under 8 MPH)
21 - 54 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

41TE AUTOMATIC TRANSAXLE
TABLE OF CONTENTS
page page
41TE AUTOMATIC TRANSAXLE
DESCRIPTION........................147
OPERATION..........................149
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - 4XTE
TRANSAXLE GENERAL DIAGNOSIS......149
DIAGNOSIS AND TESTING - ROAD TEST . . 150
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TESTS...................150
DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS...................153
DIAGNOSIS AND TESTING - TORQUE
CONVERTER HOUSING FLUID LEAKAGE . . 154
REMOVAL............................154
DISASSEMBLY........................157
ASSEMBLY...........................174
INSTALLATION........................196
SCHEMATICS AND DIAGRAMS
4XTE TRANSAXLE HYDRAULIC
SCHEMATICS.......................199
SPECIFICATIONS - 41TE TRANSAXLE......211
SPECIAL TOOLS
41TE AUTOMATIC TRANSAXLE.........213
ACCUMULATOR
DESCRIPTION........................218
OPERATION..........................218
DRIVING CLUTCHES
DESCRIPTION........................219
OPERATION..........................219
FINAL DRIVE
DESCRIPTION........................219
OPERATION..........................220
DISASSEMBLY........................220
ASSEMBLY...........................224
ADJUSTMENTS
ADJUSTMENT - DIFFERENTIAL BEARING
PRELOAD..........................228
FLUID
STANDARD PROCEDURE
FLUID LEVEL AND CONDITION CHECK . . . 230
STANDARD PROCEDURE - FLUID AND
FILTER SERVICE.....................231
GEAR SHIFT CABLE
REMOVAL............................233
INSTALLATION........................234
ADJUSTMENTS
GEARSHIFT CABLE ADJUSTMENT.......235
HOLDING CLUTCHES
DESCRIPTION........................236
OPERATION..........................236INPUT CLUTCH ASSEMBLY
DISASSEMBLY........................237
ASSEMBLY...........................246
OIL PUMP
DESCRIPTION........................261
OPERATION..........................261
DISASSEMBLY........................261
ASSEMBLY...........................263
PLANETARY GEARTRAIN
DESCRIPTION........................263
OPERATION..........................263
SEAL - OIL PUMP
REMOVAL............................264
INSTALLATION........................264
SHIFT INTERLOCK SOLENOID
DESCRIPTION........................264
OPERATION..........................265
DIAGNOSIS AND TESTING - BRAKE/
TRANSMISSION SHIFT INTERLOCK
SOLENOID..........................266
REMOVAL............................266
INSTALLATION........................267
SOLENOID/PRESSURE SWITCH ASSY
DESCRIPTION........................268
OPERATION..........................268
REMOVAL............................269
INSTALLATION........................270
SPEED SENSOR - INPUT
DESCRIPTION........................271
OPERATION..........................271
REMOVAL............................272
INSTALLATION........................272
SPEED SENSOR - OUTPUT
DESCRIPTION........................273
OPERATION..........................273
REMOVAL............................274
INSTALLATION........................274
TORQUE CONVERTER
DESCRIPTION........................275
OPERATION..........................278
REMOVAL............................280
INSTALLATION........................280
TRANSMISSION CONTROL RELAY
DESCRIPTION........................281
OPERATION..........................281
TRANSMISSION RANGE SENSOR
DESCRIPTION........................281
OPERATION..........................282
REMOVAL............................282
INSTALLATION........................282
21 - 146 41TE AUTOMATIC TRANSAXLERS

SCHEMATICS AND DIAGRAMS
4XTE TRANSAXLE HYDRAULIC SCHEMATICS
Park/Neutral (Speed Under 8 MPH)
RS41TE AUTOMATIC TRANSAXLE21 - 199
41TE AUTOMATIC TRANSAXLE (Continued)

SUNROOF
TABLE OF CONTENTS
page page
SUNROOF
DESCRIPTION........................169
DIAGNOSIS AND TESTING
SUNROOF DIAGNOSIS AND TESTING....169
DRAIN TUBE
REMOVAL............................172
INSTALLATION........................172
GLASS PANEL
REMOVAL............................173
INSTALLATION........................173
ADJUSTMENTS
SUNROOF GLASS PANEL ADJUSTMENT . . 173
SUNROOF ASSEMBLY
REMOVAL............................173
INSTALLATION........................173
SUNSHADE
REMOVAL............................173INSTALLATION........................173
WIND DEFLECTOR
REMOVAL............................174
INSTALLATION........................174
WATER CHANNEL
REMOVAL............................174
INSTALLATION........................174
SUNROOF MOTOR
REMOVAL............................174
INSTALLATION........................174
ADJUSTMENTS
ADJUSTMENT.......................175
SUNROOF SWITCH
REMOVAL............................176
INSTALLATION........................176
SUNROOF
DESCRIPTION
WARNING: Keep fingers and other body parts out
of sunroof opening at all times.
The sun roof features consists of: (Fig. 1)
²Sun roof glass
²Sun roof sun shade
The sunroof power sliding glass panel and sun-
shade can be positioned anywhere along its travel,
rearward of glass panel front edge.
The sunroof is electrically operated from a switch
located in the overhead console. To operate the sun-
roof the ignition switch must be in the Accessory or
On/Run position. Both switchs are a rocker style
design that open or close the sunroof. When pressing
and releasing the open button once, the sunroof will
express open to the comfort stop and the wind deflec-
tor will raise. If the button is pressed a second time,
the sunroof will continue to open to full travel unless
the button is released, at which time it will stop in
that position. Pressing and holding the close button
will close the sunroof. If the close button is released
before the glass fully closes, the sunroof will stop in
that position. The vent switch operates in a similar
manor. The sunroof will also operate for up to fifteen
minutes after the ignition key is turned off for cus-
tomer comfort and convenance while parking.
DIAGNOSIS AND TESTING
SUNROOF DIAGNOSIS AND TESTING
Refer to Sunroof Diagnostic Chart for possible
causes. Before beginning sunroof diagnostics verify
that all other power accessories are in proper operat-
ing condition. If not, a common electrical problem
may exist. Refer to Wiring Diagrams, in this publica-
tion for circuit, splice and component descriptions.
Check the condition of the circuit protection (20 amp
circuit breaker in the Junction Block). Inspect all
wiring connector pins for proper engagement and
continuity. Check for battery voltage at the power
sunroof controller, refer to Wiring Diagrams, for cir-
cuit information. If battery voltage of more than 10
volts is detected at the controller, proceed with the
following tests (the controller will not operate at less
than 10 volts).
Before beginning diagnosis for wind noise or water
leaks, verify that the problem was not caused by
releasing the control switch before the sunroof was
fully closed. The sunroof module has a water-man-
agement system. If however, the sunroof glass is in a
partial closed position, high pressure water may be
forced beyond the water management system bound-
aries and onto the headlining.
RSSUNROOF23 - 169

A/C COMPRESSOR CLUTCH
RELAY
DESCRIPTION
The compressor clutch relay (Fig. 7) is a Interna-
tional Standards Organization (ISO) mini-relay.
Relays conforming to the ISO specifications have
common physical dimensions, current capacities, ter-
minal patterns, and terminal functions. The ISO
mini-relay terminal functions are the same as a con-
ventional ISO relay. However, the ISO mini-relay ter-
minal pattern (or footprint) is different, the current
capacity is lower, and the physical dimensions are
smaller than those of the conventional ISO relay. The
A/C compressor clutch relay is located in the inte-
grated power module (IPM) in the engine compart-
ment. See the fuse and relay map molded into the
inner surface of the cover of the IPM for A/C com-
pressor clutch relay identification and location.
The black, molded plastic case is the most visible
component of the A/C compressor clutch relay. Five
male spade-type terminals extend from the bottom of
the base to connect the relay to the vehicle electrical
system, and the ISO designation for each terminal is
molded into the base adjacent to each terminal. The
ISO terminal designations are as follows:
²30 (Common Feed)- This terminal is con-
nected to the movable contact point of the relay.
²85 (Coil Ground)- This terminal is connected
to the ground feed side of the relay control coil.
²86 (Coil Battery)- This terminal is connected
to the battery feed side of the relay control coil.
²87 (Normally Open)- This terminal is con-
nected to the normally open fixed contact point of the
relay.²87A (Normally Closed)- This terminal is con-
nected to the normally closed fixed contact point of
the relay.
OPERATION
The A/C compressor clutch relay is an electrome-
chanical switch that uses a low current input from
the powertrain control module (PCM) to control the
high current output to the compressor clutch electro-
magnetic coil. The movable common feed contact
point is held against the fixed normally closed con-
tact point by spring pressure. When the relay coil is
energized, an electromagnetic field is produced by the
coil windings. This electromagnetic field draws the
movable relay contact point away from the fixed nor-
mally closed contact point, and holds it against the
fixed normally open contact point. When the relay
coil is de-energized, spring pressure returns the mov-
able contact point back against the fixed normally
closed contact point. The resistor or diode is con-
nected in parallel with the relay coil in the relay, and
helps to dissipate voltage spikes and electromagnetic
interference that can be generated as the electromag-
netic field of the relay coil collapses.
The compressor clutch relay terminals are con-
nected to the vehicle electrical system through a
receptacle in the integrated power module (IPM). The
inputs and outputs of the A/C compressor clutch
relay include:
²The common feed terminal (30) receives a bat-
tery current input from a fuse in the IPM through a
fused B(+) circuit at all times.
²The coil ground terminal (85) receives a ground
input from the PCM through the compressor clutch
relay control circuit only when the PCM electroni-
cally pulls the control circuit to ground.
²The coil battery terminal (86) receives a battery
current input from the PCM through a fused ignition
switch output (run-start) circuit only when the igni-
tion switch is in the On or Start positions.
²The normally open terminal (87) provides a bat-
tery current output to the compressor clutch coil
through the compressor clutch relay output circuit
only when the compressor clutch relay coil is ener-
gized.
²The normally closed terminal (87A) is not con-
nected to any circuit in this application, but provides
a battery current output only when the compressor
clutch relay coil is de-energized.
The A/C compressor clutch relay cannot be
repaired and, if faulty or damaged, it must be
replaced. Refer to the appropriate wiring information
for diagnosis and testing of the micro-relay and for
complete HVAC wiring diagrams.
Fig. 7 A/C Compressor Clutch Relay
24 - 18 CONTROLS - FRONTRS

The blower motor relay terminals are connected to
the vehicle electrical system through a receptacle in
the Integrated Power Module (IPM). The inputs and
outputs of the blower motor relay include:
²The common feed terminal (30) receives a bat-
tery current input from the battery through a B(+)
circuit at all times.
²The coil ground terminal (85) receives a ground
input through the front/rear blower motor relay con-
trol circuit only when the FCM electronically pulls
the control circuit to ground.
²The coil battery terminal (86) receives a battery
current input from the battery through a B(+) circuit
at all times.
²The normally open terminal (87) provides a bat-
tery current output to the blower motor resistor
(manual heater-A/C control) or blower power module
(automatic heater-A/C control) through a fuse in the
IPM on the fused front blower motor relay output cir-
cuit only when the blower motor relay coil is ener-
gized.
²The normally closed terminal (87A) is not con-
nected to any circuit in this application, but provides
a battery current output only when the blower motor
relay coil is de-energized.
Refer to the appropriate wiring information for
diagnosis and testing of the micro-relay and for com-
plete HVAC wiring diagrams.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the integrated power
module (IPM) (Fig. 13).
NOTE: Refer to the fuse and relay map on the inner
surface of the cover of the IPM for front blower
motor relay identification and location.
(3) Remove the front blower motor relay from the
IPM
INSTALLATION
NOTE: Refer to the fuse and relay map on the inner
surface of the cover of the integrated power module
(IPM) for front blower motor relay identification and
location.
(1) Position the front blower motor relay to the
proper receptacle in the IPM.
(2) Align the front blower motor relay terminals
with the terminal cavities in the IPM receptacle.
(3) Push down firmly on the front blower motor
relay until the terminals are fully seated in the ter-
minal cavities.
(4) Install the cover onto the IPM.(5) Reconnect the negative battery cable.
BLOWER MOTOR RESISTOR
BLOCK
DESCRIPTION
A blower motor resistor is used on this model when
it is equipped with the manual heater-A/C system.
Models equipped with the optional Automatic Tem-
perature Control (ATC) system use a blower power
module, instead of the blower motor resistor block
(Refer to 24 - HEATING & AIR CONDITIONING/
CONTROLS/POWER MODULE - DESCRIPTION).
The blower motor resistor block is mounted to the
rear of the HVAC housing, directly behind the glove
box opening in the instrument panel. The resistor
block consists of a molded plastic mounting plate
with two integral connector receptacles. Concealed
behind the mounting plate are four coiled resistor
wires contained within a protective stamped steel
cage. The blower motor resistor block is accessed for
service by removing the glove box from the instru-
ment panel.
OPERATION
The blower motor resistor block is connected to the
vehicle electrical system through a dedicated take
out and connector of the instrument panel wire har-
ness. A second connector receptacle receives the pig-
tail wire connector from the blower motor. The
blower motor resistor has multiple resistor wires,
Fig. 13 Front Blower Motor Relay
1 - INTEGRATED POWER MODULE (IPM)
2 - FRONT BLOWER MOTOR RELAY
2 - FRONT CONTROL MODULE (FCM)
24 - 24 CONTROLS - FRONTRS
BLOWER MOTOR RELAY (Continued)

each of which will reduce the current flow through
the blower motor to change the blower motor speed.
The blower motor switch in the manual heater-A/C
system directs the ground path for the blower motor
through the correct resistor wire to obtain the
selected speed.
With the blower motor switch in the lowest speed
position, the ground path for the motor is applied
through all of the resistor wires. Each higher speed
selected with the blower motor switch applies the
blower motor ground path through fewer of the resis-
tor wires, increasing the blower motor speed.
The blower motor resistor cannot be adjusted or
repaired and, if faulty or damaged, it must be
replaced.
DIAGNOSIS AND TESTING
FRONT BLOWER MOTOR RESISTOR BLOCK
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
For circuit descriptions and diagrams, refer to the
appropriate wiring information. The wiring informa-
tion includes wiring diagrams, proper wire and con-
nector repair procedures, further details on wire
harness routing and retention, as well as pin-out and
location views for the various wire harness connec-
tors, splices and grounds.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the glove box from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) Disconnect the two wire harness connectors
from the blower motor resistor block.
(4) Check for continuity between each of the
blower motor switch input terminals of the resistor
and the resistor output terminal. In each case there
should be continuity. If OK, repair the wire harness
circuits between the blower motor switch and the
blower motor resistor, blower motor or blower motorrelay as required. If not OK, replace the faulty
blower motor resistor block.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
WARNING: THE BLOWER MOTOR RESISTOR
BLOCK MAY GET VERY HOT DURING NORMAL
OPERATION. IF THE BLOWER MOTOR WAS
TURNED ON PRIOR TO SERVICING THE BLOWER
MOTOR RESISTOR BLOCK, WAIT FIVE MINUTES
TO ALLOW THE BLOWER MOTOR RESISTORS TO
COOL BEFORE PERFORMING DIAGNOSIS OR SER-
VICE. FAILURE TO TAKE THIS PRECAUTION CAN
RESULT IN PERSONAL INJURY.
CAUTION: Do not operate the blower motor with the
blower motor resistor removed from the circuit.
Failure to take this precaution can result in vehicle
damage.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the glove box from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) Disconnect the two wire harness connectors
from the blower motor resistor block (Fig. 14).
(4) Remove the two screws that secure the blower
motor resistor block to the HVAC housing.
(5) Remove the resistor block from the HVAC
housing.
INSTALLATION
(1) Position the blower motor resistor block into
the HVAC housing.
(2) Install the two screws that secure the blower
motor resistor block to the HVAC housing. Tighten
the screws to 2 N´m (17 in. lbs.).
(3) Connect the two wire connectors to the resistor
block.
RSCONTROLS - FRONT24-25
BLOWER MOTOR RESISTOR BLOCK (Continued)

²The normally open terminal (87) provides a bat-
tery current output to the blower motor resistor
(manual heater-A/C control) or blower power module
(ATC heater-A/C control) through a fuse in the IPM
on the fused rear blower motor relay output circuit
only when the blower motor relay coil is energized.
²The normally closed terminal (87A) is not con-
nected to any circuit in this application, but provides
a battery current output only when the rear blower
motor relay coil is de-energized.
Refer to the appropriate wiring information for
diagnosis and testing of the micro-relay and for com-
plete HVAC wiring diagrams.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the integrated power
module (IPM) (Fig. 5).
NOTE: Refer to the fuse and relay map on the inner
surface of the cover of the IPM for rear blower
motor relay identification and location.
(3) Remove the rear blower motor relay from the
IPM.
INSTALLATION
NOTE: Refer to the fuse and relay map on the inner
surface of the cover of the integrated power module
(IPM) for rear blower motor relay identification and
location.
(1) Position the rear blower motor relay to the
proper receptacle in the IPM.
(2) Align the rear blower motor relay terminals
with the terminal cavities in the IPM receptacle.
(3) Push down firmly on the rear blower motor
relay until the terminals are fully seated in the ter-
minal cavities.
(4) Install the cover onto the IPM.
(5) Reconnect the negative battery cable.
BLOWER MOTOR RESISTOR
BLOCK
DESCRIPTION
A rear blower motor resistor is used on this model
when it is equipped with the manual heater-A/C sys-
tem. Models equipped with the optional Automatic
Temperature Control (ATC) system use a rear blower
motor power module, instead of the blower motor
resistor block (Refer to 24 - HEATING & AIR CON-
DITIONING/CONTROLS/POWER MODULE -
DESCRIPTION). The rear blower motor resistor
block is mounted to the rear HVAC housing, directly
above the expansion valve. The resistor block con-
sists of a molded plastic mounting plate with an inte-
gral connector receptacle. Concealed behind the
mounting plate is an electrical circuit board with two
resistors and a thermal fuse. The rear blower motor
resistor block is accessed for service by removing the
right quarter and D-pillar trim panels.
OPERATION
The rear blower motor resistor block is connected
to the vehicle electrical system through a dedicated
take out and connector of the rear HVAC wire har-
ness. The blower motor resistor has an electrical cir-
cuit board with two resistors, each of which will
reduce the current flow through the blower motor to
change the blower motor speed. The blower motor
switch in the manual heater-A/C system directs the
ground path for the rear blower motor through the
correct resistor to obtain the selected speed.
Fig. 5 Rear Blower Motor Relay
1 - INTEGRATED POWER MODULE (IPM)
2 - REAR BLOWER MOTOR RELAY
3 - FRONT CONTROL MODULE (FCM)
RSCONTROLS - REAR24-37
BLOWER MOTOR RELAY (Continued)